Rotor manufacturing device and manufacturing method for rotor

Abstract

To provide a rotor manufacturing device capable of smoothly arranging a rotor magnet on an outer circumferential surface of a rotor core, and a rotor manufacturing method.SOLUTION: A rotor manufacturing device according to an embodiment has a rotor core supporting portion and a magnet supporting mechanism. The magnet supporting mechanism has a pair of supporting members and a driving unit. The pair of the support members faces each other in a facing direction perpendicular to both a radial direction and an axial direction. The pair of support members arranges a magnet between them. The driving unit moves the pair of supporting members closer to and away from each other in the facing direction. Each of the pair of supporting members has a supporting surface. The pair of supporting surfaces faces each other in the facing direction. The pair of supporting surfaces contacts the edge surface in the radial direction of the magnet. Each of the pair of supporting surfaces inclines in a direction away from each other in the facing direction as they move radially outward.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] An embodiment of the present invention relates to a rotor manufacturing apparatus and a rotor manufacturing method. [Background technology]

[0002] Surface permanent magnetic (SPM) rotors are known, in which magnets are attached to the outer periphery of the rotor core. In large rotors, the magnetic force of the magnets is also large, making it difficult to place magnets on the outer periphery of the rotor core while controlling the attractive or repulsive force of the magnets. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-10271 Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present invention is to provide a rotor manufacturing apparatus and a rotor manufacturing method that are capable of smoothly disposing a rotor magnet on the outer peripheral surface of a rotor core. [Means for solving the problem]

[0005] A rotor manufacturing apparatus according to an embodiment is a rotor manufacturing apparatus that attaches magnets to an outer peripheral surface of a rotor core that extends in an axial direction about a central axis. The rotor manufacturing apparatus has a rotor core support section and a magnet support mechanism. The rotor core support section supports the rotor core. The magnet support mechanism supports the magnets on the radially outer side of the rotor core. The magnet support mechanism has a pair of support members and a drive section. The pair of support members face each other in an opposing direction perpendicular to both the radial and axial directions. The pair of support members have a magnet disposed therebetween. The drive section moves the pair of support members toward and away from each other in the opposing direction. Each of the pair of support members has a support surface. The pair of support surfaces face each other in the opposing direction. The pair of support surfaces contact a circumferential end face of the magnet. The pair of support surfaces are inclined in a direction away from each other in the opposing direction as they move radially outward.

[0006] The manufacturing method of the rotor according to the embodiment is a manufacturing method in which a magnet is attached to the outer peripheral surface of a rotor core extending in the axial direction about a central axis. A direction perpendicular to both the radial direction and the axial direction of the central axis is defined as an opposing direction. The manufacturing method of the rotor is performed using a magnet support mechanism. The magnet support mechanism has a pair of support surfaces. The pair of support surfaces are inclined in directions that move away from each other in the opposing direction as they move radially outward. The manufacturing method of the rotor supports the magnet by bringing the circumferential end faces of the magnet into contact with the pair of support surfaces, respectively. Also, the manufacturing method of the rotor moves the pair of support surfaces away from each other in the opposing direction FD to move the magnet radially inward and attach it to the outer peripheral surface of the rotor core. [Brief description of the drawings]

[0007] [Figure 1] FIG. 2 is a schematic cross-sectional view of a rotor manufacturing apparatus according to the embodiment. [Diagram 2] 2 is a perspective view of a magnet support mechanism included in the rotor manufacturing apparatus according to the embodiment. FIG. [Diagram 3] 5A to 5C are schematic diagrams showing a magnet mounting step in the rotor manufacturing method according to the embodiment. [Figure 4] 5A to 5C are schematic diagrams showing a magnet mounting step in the rotor manufacturing method according to the embodiment. [Diagram 5] 1 is a cross-sectional view taken along a central axis of a rotating electric machine including a rotor manufactured by a manufacturing method according to an embodiment; [Figure 6] 1 is a cross-sectional view perpendicular to a central axis of a rotating electric machine including a rotor manufactured by a manufacturing method according to an embodiment. [Figure 7] FIG. 4 is a perspective view of a magnet in the rotor manufacturing method according to the embodiment. [Figure 8] FIG. 1 is a schematic diagram showing an example configuration of an aircraft. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a rotor manufacturing apparatus and a rotor manufacturing method according to an embodiment will be described with reference to the drawings. The design of the rotor manufacturing apparatus, the rotor manufactured by this rotor manufacturing apparatus, and the rotating electric machine having the rotor can be modified as appropriate to suit specifications, etc. The shapes of the components included in the rotor manufacturing apparatus, the rotor manufactured by this, and the rotating electric machine can be modified as desired, and the shapes, numbers, etc. in the drawings are only examples. Similarly, each process in the rotor manufacturing method can be modified as appropriate. The configuration of each process included in the rotor manufacturing apparatus can be modified as desired, and the state shown in the drawings is only an example.

[0009] In the following description, the direction parallel to the central axis J is simply referred to as the "axial direction," the radial direction centered on the central axis J is simply referred to as the "radial direction," and the circumferential direction centered on the central axis J is simply referred to as the "circumferential direction θ." Additionally, in each drawing, the axial direction AD, radial direction RD, and circumferential direction θ are illustrated as necessary. In each drawing, the direction in which the arrow of the axial direction AD points is referred to as the "one axial side (+AD)," and the opposite direction is referred to as the "other axial side (-AD)."

[0010] Next, a manufacturing method of rotor 20 of this embodiment and rotor manufacturing apparatus 60 will be described. Fig. 1 is a schematic cross-sectional view of rotor manufacturing apparatus 60 of this embodiment. Fig. 2 is a perspective view of a magnet support mechanism 70 of rotor manufacturing apparatus 60. Fig. 3 is a schematic view of rotor manufacturing apparatus 60 as viewed from the axial direction.

[0011] 1, the rotor manufacturing apparatus 60 of this embodiment includes, for example, a base portion 61, a rotor core support portion 62, a magnet support mechanism 70, a pressure mechanism 64, and a pair of backing plate portions 63. The rotor manufacturing apparatus 60 is an assembly device that attaches magnets 25m to the outer circumferential surface 27a of the rotor core 27 to which the shaft 21 and the hub member 23 are assembled.

[0012] The base portion 61 is placed on a floor surface or a pedestal of a factory where the rotor 20 is manufactured. The base portion 61 is, for example, a plate material placed along the floor surface. Each portion of the rotor manufacturing apparatus 60 is fixed to the base portion 61.

[0013] The rotor core support portion 62 supports the rotor core 27. The rotor core support portion 62 has, for example, a pair of support pillars 62a fixed to the base portion 61. The pair of support pillars 62a extend upward from the base portion 61. The pair of support pillars 62a are arranged on both sides of the rotor core 27 in the axial direction AD. The pair of support pillars 62a are each provided with a retaining hole 62h that penetrates in the axial direction AD. The shaft 21 is inserted into the retaining hole 62h. As a result, the pair of support pillars 62a support both ends of the shaft 21.

[0014] One of the support pillars 62a may be provided with, for example, a locking mechanism (not shown) that restricts the rotation of the shaft 21 about the central axis J. In this case, the rotor core support part 62 has a locking mechanism. The rotor core support part 62 can rotate the shaft 21 about the central axis J by releasing the locking mechanism. The rotor core support part 62 can fix the rotor core 27 in a state where a desired position of the outer circumferential surface 27a of the rotor core 27 faces the magnet support mechanism 70. Note that the locking mechanism is not necessarily provided, and instead of the locking mechanism, the rotor rotation may be restricted from the outside by a jig or the like and fixed in a predetermined position.

[0015] The magnet support mechanism 70 is disposed outside the radial direction RD of the rotor core 27 supported by the rotor core support portion 62. The magnet support mechanism 70 supports the magnet 25m outside the radial direction RD of the rotor core 27. The magnet support mechanism 70 provided in the rotor manufacturing apparatus 60 according to this embodiment is disposed, for example, directly above the rotor core 27. While supporting the magnet 25m, the magnet support mechanism 70 moves the magnet 25m to the inside in the radial direction RD and attaches it to the outer circumferential surface 27a of the rotor core 27.

[0016] As shown in FIG. 2, the magnet support mechanism 70 includes, for example, a support base 75, a pair of support members 71, a pair of connecting plate portions 72, and a drive portion 80.

[0017] The support base 75 is, for example, in the form of a plate perpendicular to the radial direction RD. The support base 75 extends, for example, along a horizontal plane. The support base 75 has, for example, a window portion 75w penetrating in the thickness direction. The outer peripheral surface 27a of the rotor core 27 is disposed directly below the window portion 75w. The magnet support mechanism 70 attaches the magnet 25m to the outer peripheral surface 27a by passing it through the window portion 75w.

[0018] The support member 71 is, for example, a block-shaped member. The support member 71 is made of a non-magnetic material. Examples of materials used for the support member 71 include aluminum alloys, non-magnetic stainless steel, and titanium alloys, but other non-magnetic materials may also be used. The support member 71 is located above a support base 75. The support member 71 is mounted on the drive unit 80 via a connecting plate unit 72.

[0019] The pair of support members 71 face each other in a direction perpendicular to both the radial direction RD and the axial direction AD. In the following description, the direction perpendicular to both the radial direction RD and the axial direction AD is referred to as the facing direction FD. In the facing direction FD, a magnet 25m is disposed between the pair of support members 71. In the following description, when distinguishing between the pair of support members 71, one located on one side of the facing direction FD is referred to as a first support member 71A, and the other located on the other side of the facing direction FD is referred to as a second support member 71B.

[0020] 3, the pair of support members 71 each have a support surface 71f. Each of the pair of support surfaces 71f is a flat surface. The pair of support surfaces 71f face each other in the facing direction FD. The pair of support surfaces 71f are inclined in directions away from each other in the facing direction FD as they move outward in the radial direction RD.

[0021] In this specification, the angle between the pair of support surfaces 71f is referred to as the support surface angle α. The pair of support surfaces 71f can move toward and away from each other in the opposing direction FD by the function of the drive unit 80 described below. It is preferable that the support surface angle α is a constant angle regardless of the approach and separation of the support surfaces 71f.

[0022] The support surface 71f of the first support member 71A contacts one end face 25a of the magnet 25m in the circumferential direction θ. Meanwhile, the support surface 71f of the second support member 71B contacts one end face 25a of the magnet 25m in the circumferential direction θ. In this embodiment, the support surface angle α is approximately equal to the magnet end face angle φ (see FIG. 6). In this specification, the magnet end face angle φ is the angle between both end faces 25a of the magnet 25m in the circumferential direction θ. The magnet end face angles φ of all the magnets 25m are approximately equal.

[0023] When the pair of support surfaces 71f move away from each other while the magnet 25m is sandwiched between them, the end surface 25a in the circumferential direction θ of the magnet 25m slides on the support surfaces 71f and moves downward. As the pair of support surfaces 71f move away from each other, the magnet 25m moves inward in the radial direction RD while maintaining its position.

[0024] In this embodiment, it is preferable that the support surface angle α is kept within ±10° of the magnet end face angle φ regardless of the distance between the pair of support members 71. In other words, whether the pair of support surfaces 71f are driven by the drive unit 80 to be separated from each other or to be close to each other, it is preferable that the difference between the support surface angle α and the magnet end face angle φ is 10° or less. In this way, even if the support members 71 are moved close to each other by the drive unit 80, since the support surface angle α is approximately equal to the magnet end face angle φ, the attitude of the magnet 25m can be maintained regardless of the movement of the magnet 25m in the radial direction RD.

[0025] 2, the distance between the support surfaces 71f at ends on one side in the axial direction AD is defined as a first distance d1. Meanwhile, the distance between the support surfaces 71f at ends on the other side in the axial direction AD is defined as a second distance d2. Because the distance between the pair of support surfaces 71f increases toward the upper side, both the first distance d1 and the second distance d2 are the distance between the lower ends of the pair of support surfaces 71f.

[0026] In this embodiment, the absolute value of the difference between the first distance d1 and the second distance d2 (|d1-d2|) is preferably kept at 10 μm or less, and more preferably at 5 μm or less, regardless of the distance between the pair of support members 71. That is, whether the pair of support surfaces 71f are driven by the drive unit 80 to be separated from each other or to be close to each other, the difference between the first distance d1 and the second distance d2 is ±10 μm or less, more preferably ±5 μm or less. In this way, even if the support members 71 are moved close to each other by the drive unit 80, by making the absolute value of the difference between the first distance d1 and the second distance d2 10 μm or less, more preferably 5 μm or less, the magnet 25m can be supported by the magnet support mechanism 70 without rattling regardless of the movement of the magnet 25m in the radial direction RD.

[0027] The surface of the support surface 71f is preferably subjected to a surface treatment for reducing frictional resistance. For example, a surface coating may be formed as the surface treatment. A film for reducing friction between the surface of the support surface 71f and the end surface 25a of the magnet 25m may be attached to the surface of the support surface 71f. This can prevent the magnet 25m from being damaged when the magnet 25m slides on the support surface 71f.

[0028] The pair of support members 71 may be provided with, for example, slits extending upward from the lower ends of the support surfaces 71f. In this case, it is preferable that the slits of the pair of support members 71 are shifted in the axial direction AD, and the pair of support members 71 cross each other so that they are inserted into each other's slits when approaching each other. In this case, by crossing the support members 71, the magnet support mechanism 70 can further separate the magnet 25m from the rotor core 27. This allows the magnet 25m to be placed between the pair of support surfaces 71f in a place where the attractive force between the magnet 25m and the rotor core 27 does not affect, making the preliminary work easier.

[0029] As shown in FIG. 2, the pair of connecting plate parts 72 are, for example, plate-shaped along a horizontal plane. The pair of connecting plate parts 72 extend parallel to each other along the axial direction AD. In the following description, when distinguishing between the pair of connecting plate parts 72, one located on one side of the opposing direction FD is called the first connecting plate part 72A, and the other located on the other side of the opposing direction FD is called the second connecting plate part 72B. The first supporting member 71A is mounted and fixed on the first connecting plate part 72A. On the other hand, the second connecting plate part 72B is mounted and fixed on the second supporting member 71B. Furthermore, the first connecting plate part 72A and the second connecting plate part 72B are mounted and fixed on the driving part 80, respectively.

[0030] As will be described later with reference to Fig. 4, each of the pair of connecting plate parts 72 has a removable spacer (adjustment part) 72s. The connecting plate part 72 can adjust the height of the support member 71 by disposing a plate-shaped spacer 72s between the connecting plate part 72 and the support member 71. The spacer 72s is an example of an adjustment part that adjusts the height, and other configurations may be adopted.

[0031] 2, the driving unit 80 has, for example, a slide mechanism 85 and a screw driving mechanism 81. The driving unit 80 moves the pair of support members 71 toward and away from each other in the facing direction FD.

[0032] The slide mechanism 85 and the screw drive mechanism 81 are mounted on and fixed to the support base 75. The slide mechanism 85 is located on one axial side (+AD) of the window portion 75w and extends in the opposing direction FD. On the other hand, the screw drive mechanism 81 is located on the other axial side (-AD) of the window portion 75w and extends along the opposing direction FD.

[0033] The screw drive mechanism 81 has, for example, a rotating shaft 82, a pair of bearings 83, and a pair of nuts 84. The rotating shaft 82 extends along the opposing direction FD. For example, a first male screw portion 82a and a second male screw portion 82b are provided on the outer periphery of the rotating shaft 82. The first male screw portion 82a and the second male screw portion 82b are arranged side by side in the longitudinal direction of the rotating shaft 82. The first male screw portion 82a and the second male screw portion 82b are reverse-threaded. That is, one of the first male screw portion 82a and the second male screw portion 82b is a right-handed screw, and the other is a left-handed screw.

[0034] For example, an actuator (not shown) is connected to one end of the rotating shaft 82. The rotating shaft 82 is rotated by the actuator. Note that, instead of the actuator, for example, a handle may be provided to one end of the rotating shaft 82. In this case, a worker who installs the magnet 25m rotates the rotating shaft 82 using the handle.

[0035] The pair of bearings 83 are arranged side by side in the opposing direction FD. The pair of bearings 83 rotatably support the rotating shaft 82. Furthermore, the axial movement of the rotating shaft 82 is restricted with respect to the pair of bearings 83. The first male thread portion 82a and the second male thread portion 82b of the rotating shaft 82 are arranged between the pair of bearings 83.

[0036] The nut portion 84 is, for example, block-shaped. The nut portion 84 is provided with a screw hole penetrating in the facing direction FD. In addition, a female screw portion is formed on the inner peripheral surface of the screw hole. The female screw portions of the pair of nut portions 84 are reverse-threaded. The first male screw portion 82a is inserted into one of the pair of nut portions 84, and the second male screw portion 82b is inserted into the other. For example, trapezoidal screws can be used as the first male screw portion 82a and the second male screw portion 82b and the pair of nut portions 84. One of the pair of nut portions 84 located on one side of the facing direction FD is fixed to an end portion of the other axial side (-AD) of the first connecting plate portion 72A. The other of the pair of nut portions 84 located on the other side of the facing direction FD is fixed to an end portion of the other axial side (-AD) of the second connecting plate portion 72B.

[0037] The slide mechanism 85 has, for example, a rail portion 85a and a pair of block portions 85b. The rail portion 85a extends along the facing direction FD. The pair of block portions 85b are assembled to the rail portion 85a while being aligned in the facing direction FD. The pair of block portions 85b can independently slide along the facing direction FD on the rail portion 85a. One of the pair of block portions 85b, which is located on one side of the facing direction FD, is fixed to an end portion of one axial side (+AD) of the first connecting plate portion 72A. The other of the pair of block portions 85b, which is located on the other side of the facing direction FD, is fixed to an end portion of one axial side (+AD) of the second connecting plate portion 72B.

[0038] According to this embodiment, the nut portion 84 moves in the opposing direction FD by rotating the rotating shaft 82 by the actuator. Since the female threads provided on the pair of nut portions 84 are reverse threads, the pair of nut portions 84 always move in opposite directions at the same speed along the opposing direction FD. One nut portion 84 and one block portion 85b are connected to each other via the first connecting plate portion 72A. The other nut portion 84 and the other block portion 85b are connected to each other via the second connecting plate portion 72B. Therefore, the first connecting plate portion 72A and the second connecting plate portion 72B always move in opposite directions at the same speed in the opposing direction FD. Also, the first support member 71A mounted on the first connecting plate portion 72A and the second support member 71B mounted on the second connecting plate portion 72B always move in opposite directions at the same speed in the opposing direction FD. That is, the driving unit 80 included in the rotor manufacturing apparatus 60 according to this embodiment moves the pair of support members 71 in opposite directions to each other at the same speed along the facing direction FD.

[0039] The pair of support members 71 move in parallel along the opposing direction FD. Therefore, the support surfaces 71f of the pair of support members 71 can move toward and away from each other while maintaining the support surface angle α (see FIG. 3). As the pair of support surfaces 71f move toward and away from each other, the gap between the pair of support surfaces 71f narrows or widens. Accordingly, the magnet 25m sandwiched between the pair of support surfaces 71f can move in the radial direction of the central axis J.

[0040] 3, the pressure mechanism 64 applies pressure to the outer surface 25c of the magnet 25m supported by the magnet support mechanism 70 in a direction toward the inside in the radial direction RD of the central axis J. As a result, the pressure mechanism 64 presses the magnet 25m against a pair of support surfaces 71f. The pressure mechanism 64 has, for example, a pressure unit 64a, a spring unit 64b, and a lifting unit (not shown).

[0041] The pressure applying unit 64a has a contact surface 64c that is curved along the outer surface 25c of the magnet 25m. A member having a high elasticity, such as rubber or elastomer resin, may be attached to the contact surface 64c. This can prevent the outer surface of the magnet 25m from receiving a large force locally from the pressure applying mechanism 64, and can prevent damage to the magnet 25m.

[0042] The spring portion 64b applies a force to the pressure applying portion 64a toward the outer surface 25c of the magnet 25m. The lifting portion (not shown) raises and lowers the pressure applying portion 64a and the spring portion 64b in the vertical direction. The lifting portion can also be driven in conjunction with the screw drive mechanism 81 of the magnet support mechanism 70. That is, the lifting portion raises and lowers the pressure applying portion 64a and the spring portion 64b in accordance with the height of the magnet 25m, which rises and falls according to the approach and separation of the pair of support surfaces 71f, thereby always applying a constant pressure to the outer surface 25c of the magnet 25m. This allows a constant frictional force to be applied between the circumferential end surface 25a of the magnet 25m and the support surface 71f of the magnet support mechanism 70, and the magnet 25m can be smoothly moved inward in the radial direction RD with the operation of the pair of support members 71.

[0043] As shown in Fig. 2, the pair of backing plate portions 63 are mounted and fixed, for example, on a support base 75. The pair of backing plate portions 63 face each other in the axial direction AD with a window portion 75w therebetween. As shown in Fig. 1, the pair of backing plate portions 63 are located on both sides in the axial direction AD of the magnet 25m supported by the magnet support mechanism 70. The pair of backing plate portions 63 are made of, for example, a resin material or a non-magnetic metal material.

[0044] As shown in FIG. 1, the pair of contact plate portions 63 have contact surfaces 63f. The pair of contact plate portions 63 may have guide surfaces 63a in addition to the contact surfaces 63f. The contact surfaces 63f are perpendicular to the axial direction AD. The contact surfaces 63f extend in the up-down direction (i.e., the radial direction RD). The pair of contact surfaces 63f face each other in the axial direction AD. The distance between the pair of contact surfaces 63f is approximately the same as or slightly larger than the dimension of the magnet 25m in the axial direction AD. According to this embodiment, the magnet 25m is positioned in the axial direction AD by being disposed between the pair of contact surfaces 63f. This makes it possible to position and attach the magnet 25m in the axial direction AD with respect to the rotor core 27.

[0045] A pair of guide surfaces 63a located above the contact surface 63f and connected to the contact surface 63f are spaced apart from each other as they move upward. In the manufacturing method of the rotor 20 of this embodiment, by moving the magnet 25m from above the pair of contact plate portions 63 to below, the axial end face of the magnet 25m comes into contact with the guide surfaces 63a, and the magnet 25m is moved in the axial direction AD, so that the magnet 25m can be smoothly guided between the pair of contact surfaces 63f.

[0046] Fig. 4 is a schematic diagram of rotor manufacturing apparatus 60 as viewed from the axial direction, similar to Fig. 3. Figs. 3 and 4 are also diagrams showing the steps of a method for manufacturing rotor 20. Here, an example of a magnet attachment process for attaching magnets 25m to outer peripheral surface 27a of rotor core 27 will be described, among the steps of the method for manufacturing rotor 20.

[0047] In the following description, when it is necessary to distinguish between the magnetization directions of the multiple magnets 25m provided in the rotor 20 that are opposite to each other in the radial direction RD, these magnets are referred to as the first magnet 25s and the second magnet 25n, respectively. Here, the first magnet 25s is a magnet that forms an S pole on the outside of the radial direction RD, and the second magnet 25n is a magnet that forms an N pole on the outside of the radial direction RD. In addition, when it is not necessary to distinguish between the first magnet 25s and the second magnet 25n, these are simply referred to as magnets 25m.

[0048] In the manufacturing method of this embodiment, the process of attaching the magnets 25m of the rotor 20 is performed in, for example, two stages. In the first stage, the first magnets 25s are attached to the rotor core 27. In the second stage, the second magnets 25n are attached to the rotor core 27. In the following description, the procedure of attaching the first magnets 25s to the rotor core 27 is called the first stage, and the procedure of attaching the second magnets 25n is called the second stage. The order of the first and second stages may be reversed from that of this embodiment. The number of magnets 25m is not limited to this embodiment and is appropriately selected according to the magnetic design of the rotating electric machine 1. For this reason, in the manufacturing method of the rotor 20, the number of magnet attachment steps is appropriately set according to the number of selected magnets 25m.

[0049] Fig. 3 shows the first step. In carrying out the magnet attachment process, adhesive is applied to the outer peripheral surface 27a of the rotor core 27, or the inner peripheral surface of the magnet 25m, or both. Also, as shown in Fig. 1, in the magnet attachment process, the rotor core 27 is supported and fixed by the rotor core support portion 62. This limits the movement of the rotor core 27 in the axial direction AD and the circumferential direction θ.

[0050] 3, in the magnet attachment process, the magnet 25m is first placed between a pair of support surfaces 71f. Then, the circumferential end faces 25a of the magnet 25m are brought into contact with the pair of support surfaces 71f, respectively. As a result, the pair of support surfaces 71f support the magnet 25m.

[0051] Next, the pair of support surfaces 71f are moved away from each other in the facing direction FD, thereby moving the magnet 25m inward in the radial direction RD. The magnet support mechanism 70 further widens the gap between the pair of support members 71 while the magnet 25m is in contact with the outer circumferential surface 27a of the rotor core 27. This causes the pair of support surfaces 71f to move away from the magnet 25m, releasing support for the magnet 25m. An attractive force acts between the magnet 25m and the rotor core 27. Therefore, a surface pressure acts between the inner surface of the magnet 25m and the outer circumferential surface 27a of the rotor core 27, and the magnet 25m is adhered to the outer circumferential surface 27a of the rotor core 27 without any gaps.

[0052] In the first step, the process of attaching the first magnets 25s is repeated the number of times corresponding to the number of first magnets 25s, thereby attaching a plurality of first magnets 25s to the outer peripheral surface 27a of the rotor core 27. After attaching one first magnet 25s, the rotor core 27 is rotated about the central axis J. This allows the plurality of first magnets 25s to be arranged side by side in the circumferential direction on the outer peripheral surface 27a of the rotor core 27. When rotating the rotor core 27, for example, a locking mechanism that locks the rotation of the rotor core by the rotor core support portion 62 shown in FIG. 1 is released, and after the rotor core 27 is rotated by a predetermined angle, the locking mechanism is operated again.

[0053] FIG. 4 shows the second step. As shown in FIG. 4, in the magnet mounting step of the second step, the second magnet 25n is disposed between the first magnets 25s arranged with a gap in the circumferential direction θ. In the second step, if the distance between the support member 71 and the outer peripheral surface 27a of the rotor core 27 is too close, the support member 71 may come into contact with the first magnet 25s. Therefore, before performing the second step, a spacer 72s is interposed between the support member 71 and the connecting plate portion 72 to separate the support member 71 from the outer peripheral surface 27a of the rotor core 27. That is, the manufacturing method of the rotor 20 of this embodiment has a position adjustment step performed between the first step and the second step. The position adjustment step is a step of changing the radial distance of the support member 71 with respect to the central axis J.

[0054] The spacer 72s is, for example, a plate having a thickness equal to that of the magnet 25m. By interposing the spacer 72s between the support member 71 and the connecting plate portion 72, the pair of support members 71 can be moved outward in the radial direction RD. This makes it possible to prevent the support member 71 from contacting the first magnet 25s attached to the outer circumferential surface 27a of the rotor core 27.

[0055] As shown in Fig. 4, in the magnet attachment step of the second procedure, the pair of support surfaces 71f are also moved away from each other in the opposing direction FD to move the magnet 25m inward in the radial direction RD. The magnet support mechanism 70 further widens the gap between the pair of support members 71 while bringing the magnet 25m as close as possible to the outer peripheral surface 27a of the rotor core 27. This causes the pair of support surfaces 71f to move away from the magnet 25m, releasing support for the magnet 25m. The magnet 25m moves away from the support surfaces 71f and is attracted to the outer peripheral surface 27a of the rotor core 27.

[0056] Although not shown, in the second step, the process of attaching the second magnets 25n is repeated the same number of times as the number of second magnets 25n as in the first step, thereby attaching the second magnets 25n to the outer peripheral surface 27a of the rotor core 27. The adhesive may be cured each time a magnet is attached, or may be cured after the first step or the second step, or may be cured after the first step and the second step. In this way, all the magnets 25m are attached to the outer peripheral surface 27a of the rotor core 27. Furthermore, after this, a cover is attached to the outer surface 25c of the magnets 25m, thereby completing the manufacturing process of the rotor 20.

[0057] The configuration, effects and advantages of the rotor manufacturing apparatus 60 and the method for manufacturing the rotor 20 according to this embodiment will be summarized below. The rotor manufacturing apparatus 60 of this embodiment is a rotor manufacturing apparatus (60) that attaches a magnet 25m to an outer peripheral surface 27a of a rotor core 27 that extends in the axial direction centered on a central axis J. The rotor manufacturing apparatus 60 includes a rotor core support portion 62 and a magnet support mechanism 70. The rotor core support portion 62 supports the rotor core 27. The magnet support mechanism 70 supports the magnet 25m on the outer side of the rotor core 27 in the radial direction RD. The magnet support mechanism 70 includes a pair of support members 71 and a drive portion 80. The pair of support members 71 face each other in a facing direction FD that is perpendicular to both the radial direction RD and the axial direction AD. The pair of support members 71 arrange the magnet 25m therebetween. The drive portion 80 moves the pair of support members 71 toward or away from each other in the facing direction FD. The pair of support members 71 each have a support surface 71f. The pair of support surfaces 71f face each other in the facing direction FD. The pair of support surfaces 71f contact the end surface 25a of the magnet 25m in the circumferential direction θ. The pair of support surfaces 71f are inclined in directions away from each other in the facing direction FD as they move outward in the radial direction RD.

[0058] According to this configuration, the magnet 25m can be moved inward in the radial direction RD by separating the pair of support members 71 with the drive unit 80 while the magnet 25m is disposed between them. Therefore, even if a large attractive or repulsive force is applied to the magnet 25m inward in the radial direction RD due to the magnetic force of the magnet 25m, the magnet 25m can be moved closer to the outer circumferential surface 27a of the rotor core 27 while maintaining the orientation of the magnet 25m. As a result, the magnet 25m can be attached to the outer circumferential surface 27a of the rotor core 27 with good positional accuracy and while suppressing impact.

[0059] In the rotor 20 manufactured by the manufacturing method of this embodiment, a samarium cobalt (SmCo) magnet is used as the magnet 25m. The samarium cobalt magnet has superior heat resistance compared to other common rare earth magnets such as neodymium magnets, and is known to maintain high magnetic properties even at high temperatures of 150°C or higher. When the rotating electric machine 1 is mounted on a moving body such as an aircraft 90, for example, it is required to reduce the size and weight. For this reason, it is difficult to adopt a complex or large cooling structure and heat dissipation structure for the rotating electric machine 1. According to this embodiment, by adopting a samarium cobalt magnet as the magnet 25m, it is possible to configure a rotating electric machine 1 that exhibits sufficient torque performance even when the magnet 25m becomes hot. As a result, it is possible to simplify the cooling structure and heat dissipation structure of the rotating electric machine 1. However, on the other hand, the samarium cobalt magnet is prone to chipping when it is subjected to an impact. In addition, it is difficult to magnetize the samarium cobalt magnet by post-magnetization, i.e., magnetizing after assembly to the rotor core. For this reason, when using samarium-cobalt magnets as the magnets 25m of the rotor 20, it is necessary to attach the magnetized magnets 25m to the outer circumferential surface of the rotor core without subjecting them to impact and while maintaining high dimensional accuracy. According to the rotor manufacturing apparatus 60 of this embodiment, it is possible to attach the magnets 25m to the rotor core 27 without damaging the magnets 25m, which are made of samarium-cobalt magnets that are susceptible to breakage due to such impacts.

[0060] In this embodiment, the angle between both end faces 25a of the magnet 25m in the circumferential direction θ is defined as the magnet end face angle φ. The angle between a pair of support faces 71f is defined as the support face angle α. It is preferable that the support face angle α be kept within ±10° of the magnet end face angle φ, regardless of the distance between the pair of support members 71.

[0061] This configuration stabilizes the contact between the end surface 25a of the magnet 25m and the support surface 71f when the magnet 25m is moved in the radial direction RD, thereby preventing the magnet 25m from wobbling. This allows the magnet 25m to be smoothly attached to the outer circumferential surface 27a of the rotor core 27.

[0062] In this embodiment, it is preferable that the absolute value (|d1-d2|) of the difference between the distance (first distance d1) at one end of the support surfaces 71f in the axial direction AD and the distance (second distance d2) at the other end of the support surfaces 71f in the axial direction AD is kept equal to or less than 10 μm, preferably equal to or less than 5 μm, regardless of the distance between the pair of support members 71.

[0063] According to this configuration, when the magnet 25m is moved in the radial direction RD, the gap between the end of the support surface 71f on one or the other axial side and the end face 25a of the magnet 25m can be made sufficiently small, about 10 μm (more preferably about 5 μm). This makes it possible to prevent the magnet 25m from rattling when the magnet 25m is moved, and makes it possible to smoothly attach the magnet 25m to the outer circumferential surface 27a of the rotor core 27.

[0064] The rotor manufacturing apparatus 60 of this embodiment may include a pair of backing plate portions 63. The pair of backing plate portions 63 are located on both sides in the axial direction AD of the magnet 25m supported by the magnet support mechanism 70. The pair of backing plate portions 63 each have a backing surface 63f. The pair of backing surfaces 63f face each other. The pair of backing surfaces 63f are perpendicular to the axial direction AD.

[0065] According to this configuration, by appropriately setting the distance between the contact surfaces 63f, the magnet 25m can be aligned in the axial direction AD between the contact surfaces 63f. This makes it possible to attach the magnet 25m to the rotor core 27 while positioning it in the axial direction AD.

[0066] In the rotor manufacturing apparatus 60 of this embodiment, the magnet support mechanism 70 can have a spacer (adjustment portion) 72s that changes the distance in the radial direction RD of the pair of support members 71 relative to the central axis J.

[0067] When attaching the magnets 25m to the outer peripheral surface 27a of the rotor core 27, it is preferable to attach all magnets of one pole (e.g., the first magnets 25s) of the N pole or the S pole before attaching all magnets of the other pole (e.g., the second magnets 25n) in order to suppress repulsion between the magnets 25m. According to the above-mentioned configuration, since the rotor manufacturing apparatus 60 has the spacer 72s, when attaching the magnets of one pole, the support member 71 can be brought close to the outer peripheral surface 27a of the rotor core 27. Also, when attaching the magnets of the other pole, the magnets can be placed at a certain distance or more from the outer peripheral surface 27a of the rotor core 27 between the magnets 25m of one pole that have already been attached, while avoiding contact with the magnets 25m.

[0068] The rotor manufacturing apparatus 60 of this embodiment may include a pressure mechanism 64. The pressure mechanism 64 presses the magnet 25m supported by the magnet support mechanism 70 against a pair of support surfaces 71f.

[0069] This configuration can prevent the end face 25a of the magnet 25m in the circumferential direction θ from lifting up from the support surface 71f. This allows a certain frictional force to be applied between the end face 25a of the magnet 25m in the circumferential direction and the support surface 71f of the magnet support mechanism 70, allowing the magnet 25m to move smoothly inward in the radial direction RD as the pair of support members 71 move.

[0070] In the rotor manufacturing apparatus 60 of this embodiment, the driving unit 80 can move the pair of support members 71 in opposite directions to each other along the facing direction FD at the same speed.

[0071] According to this configuration, the magnet 25m can be brought closer to the outer peripheral surface 27a of the rotor core 27 without moving it in the circumferential direction θ. Therefore, when the magnet 25m is brought closer to the rotor core 27, the orientation of the magnet 25m is easily maintained constant, and the magnet 25m can be smoothly attached to the outer peripheral surface 27a of the rotor core 27.

[0072] The manufacturing method of the rotor 20 of this embodiment is a manufacturing method in which the magnet 25m is attached to the outer peripheral surface 27a of the rotor core 27 extending in the axial direction AD centered on the central axis J. In this embodiment, the direction perpendicular to both the radial direction RD and the axial direction AD of the central axis J is defined as the facing direction FD. The manufacturing method of the rotor 20 is performed using a magnet support mechanism 70. The magnet support mechanism 70 has a pair of support surfaces 71f. The pair of support surfaces 71f are inclined in directions away from each other in the facing direction FD as they move outward in the radial direction RD. The manufacturing method of the rotor 20 supports the magnet 25m by bringing the end faces 25a of the magnet 25m in the circumferential direction θ into contact with the pair of support surfaces 71f, respectively. Also, the manufacturing method of the rotor 20 moves the pair of support surfaces 71f away from each other in the facing direction FD, thereby moving the magnet 25m inward in the radial direction RD and attaching it to the outer peripheral surface 27a of the rotor core 27.

[0073] With this configuration, even if a large attractive or repulsive force toward the rotor core 27 is applied to the magnet 25m due to the magnetic force of the magnet 25m, it is possible to maintain the orientation of the magnet 25m while bringing the magnet 25m closer to the outer circumferential surface 27a of the rotor core 27. As a result, the magnet 25m can be attached to the outer circumferential surface 27a of the rotor core 27 with good positional accuracy and while suppressing impacts.

[0074] According to at least one of the embodiments described above, it is possible to provide a rotor manufacturing apparatus and a rotor manufacturing method that can smoothly arrange rotor magnets on the outer circumferential surface of a rotor core. A rotor 20 manufactured by the manufacturing method according to the present embodiment and a rotating electric machine 1 having the rotor 20 will be described.

[0075] Fig. 5 is a cross-sectional view taken along the central axis J of the rotating electric machine 1. Fig. 6 is a cross-sectional view of the rotor 20.

[0076] 5, the rotating electric machine 1 includes, for example, an annular stator 30 centered on a central axis J, a rotor 20 positioned inside the stator 30 in the radial direction RD, and a cylindrical housing 10 that accommodates the stator 30 and the rotor 20. The rotating electric machine 1 in FIG. 5 is an inner rotor type rotating electric machine in which the rotor 20 is positioned inside the stator 30 in the radial direction RD.

[0077] The housing 10 has, for example, a housing main body 12 extending along the axial direction AD and surrounding the stator 30 from the outside in the radial direction RD, a bearing holder 11 fixed to the ends of the housing main body 12 on one axial side (+AD) and the other axial side (-AD), respectively, and a heat dissipation fin 12f.

[0078] The bearing holder 11 is, for example, disk-shaped and centered on the central axis J. The pair of bearing holders 11 each cover an opening on both axial sides of the housing body 12. The bearing holder 11 is fixed, for example, to an end face of the housing body 12 facing the axial direction AD using a bolt (not shown). The housing body 12 holds a bearing B in the center. The bearing B supports the shaft 21 of the rotor 20 so as to be freely rotatable.

[0079] 5, the stator 30 surrounds the rotor 20 from the outside in the radial direction RD. The stator 30 includes a stator core 31 and a coil 40.

[0080] The rotor 20 is supported by the housing 10 so as to be rotatable about a central axis J. The rotor 20 includes a shaft 21 having a central axis J, a hub member 23, a rotor core 27, a magnet unit 25, and a cover 26.

[0081] The shaft 21 is, for example, cylindrical and extending in the axial direction AD about a central axis J. The hub member 23 is, for example, cylindrical and having a sufficient thickness in the radial direction RD. The hub member 23 may be provided with a plurality of through holes penetrating in the axial direction AD. The hub member 23 is fixed, for example, to the outer circumferential surface of the shaft 21. In addition, a rotor core 27 is fixed, for example, to the outer circumferential surface of the hub member 23.

[0082] The rotor core 27 is made of a magnetic material. For example, the rotor core 27 is a laminated steel plate formed by stacking a plurality of electromagnetic steel plates in the axial direction AD. The rotor core 27 extends in the axial direction AD about a central axis J. The rotor core 27 in FIG. 6 is, for example, cylindrical. The magnet unit 25 is disposed on the outer peripheral surface 27a of the rotor core 27.

[0083] The magnet unit 25 has, for example, a circular ring shape. The magnet unit 25 can be fixed to the outer circumferential surface of the rotor core 27 by a joining means such as adhesive. The rotor 20 in FIG. 6 is a surface magnet type in which the magnet unit 25 directly faces the stator 30 magnetically.

[0084] The magnet unit 25 has a plurality of first magnets 25s and a plurality of second magnets 25n. The first magnets 25s and the second magnets 25n are arranged alternately in the circumferential direction θ. That is, the magnet unit 25 has a plurality of magnets 25m whose magnetization directions alternate in the circumferential direction θ.

[0085] As shown in FIG. 6, the magnet 25m extends, for example, in an arc shape centered on the central axis J when viewed from the axial direction AD. The magnet 25m is plate-shaped with the radial direction RD as its thickness direction. An inner surface of the magnet 25m facing inward in the radial direction RD is adhesively fixed to the outer surface of the rotor core 27. An outer surface 25c of the magnet 25m facing outward in the radial direction RD is covered, for example, by a cylindrical cover 26. The cover 26 surrounds the magnet unit 25 and prevents the multiple magnets 25m from detaching from the rotor core 27. The cover 26 is made of a material that is unlikely to affect the magnetic force of the magnet unit 25.

[0086] The magnet 25m has a pair of end faces 25a facing one side and the other side in the circumferential direction θ. The end faces 25a are, for example, flat surfaces extending in the radial direction. In this specification, the angle between both end faces 25a of the magnet 25m in the circumferential direction θ is defined as the magnet end face angle φ. The magnet end face angles φ of all the magnets 25m including the first magnet 25s and the second magnet 25n are approximately equal.

[0087] FIG. 7 is a perspective view of a magnet 25m as an example. The magnet 25m may be divided. Here, a divided magnet will be described as an example. The magnet 25m has a plurality of element magnets 25e stacked in the axial direction AD. The plurality of element magnets 25e are, for example, sintered magnets. The element magnets 25e aligned in the axial direction AD are bonded to each other via adhesive layers 25b. The magnetization directions of the stacked element magnets 25e are the radial direction RD and are the same. The plurality of element magnets 25e shown in FIG. 7 are magnetized after being bonded to each other via adhesive layers 25b, for example.

[0088] 7 is formed by joining a plurality of element magnets 25e. Therefore, compared to a case where the magnet is formed from a single sintered magnet, the value of the eddy current flowing through each element magnet 25e can be made smaller, and the eddy current loss generated in the magnet 25m as a whole can be reduced. This suppresses heat generation in the magnet 25m caused by eddy currents generated in the magnet 25m, reduces a decrease in the magnetic force of the magnet 25m, and improves the torque performance of the rotating electric machine 1.

[0089] 7, the adhesive layer 25b that bonds the element magnets 25e together is preferably made of an insulating material. In this case, it is possible to prevent current from flowing between the bonded element magnets 25e, and to effectively suppress eddy current loss in the magnet 25m. In addition, the element magnets 25e may be insulated from each other by, for example, forming an insulating coating on the surface of the element magnets 25e.

[0090] In the example shown in Fig. 7, the element magnet 25e is composed of a samarium-cobalt magnet. That is, the magnet 25m in Fig. 7 is a samarium-cobalt magnet. Samarium-cobalt magnets have superior heat resistance compared to other common rare earth magnets such as neodymium magnets, and are known to maintain high magnetic properties even at high temperatures of, for example, 150°C or higher, at which the magnetic force of neodymium magnets drops significantly. By using a samarium-cobalt magnet as the magnet 25m, it is possible to configure a rotating electric machine 1 that exhibits sufficient torque performance even when the magnet 25m becomes hot.

[0091] The rotating electric machine can be mounted on various drive objects such as automobiles, trains, and aircraft. Fig. 8 is a schematic diagram of an aircraft 90 as an example of a drive object on which the rotating electric machine 1 is mounted. The aircraft 90 is a hybrid aircraft propelled by a combination of a jet engine 91 and the rotating electric machine 1. The aircraft 90 has a pair of jet engines 91 and four rotating electric machines 1. The jet engines 91 are provided on main wings 98. The jet engines 91 generate thrust by exhausting air rearward.

[0092] The four rotating electric machines 1 are classified into two power generating rotating electric machines 1A and two drive rotating electric machines 1B. The power generating rotating electric machines 1A are each connected to the main shaft of a jet engine 91. The power generating rotating electric machine 1A generates electricity by the jet engine 91. Meanwhile, the drive rotating electric machine 1B is disposed below the vertical tail 99. The drive rotating electric machine 1B rotates a propulsion fan 93 to send air rearward and generate thrust. The drive rotating electric machine 1B is driven by electric power generated by the power generating rotating electric machine 1A. Note that if the power generating rotating electric machine 1A generates surplus electric power, this electric power may be charged into a battery and used when necessary.

[0093] Although some embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope of the invention and its equivalents described in the claims, as well as in the scope and spirit of the invention. [Explanation of symbols]

[0094] 20...rotor, 25a...end surface, 25a...both end surfaces, 25m...magnet, 27...rotor core, 27a...outer peripheral surface, 60...rotor manufacturing apparatus, 62...rotor core support portion, 63...plate portion, 63f...surface, 64...pressure mechanism, 70...magnet support mechanism, 71...support member, 71f...support surface, 72s...spacer (adjustment portion), 80...drive portion, AD...axial direction, FD...opposing direction, J...central axis, RD...radial direction, α...support surface angle, θ...circumferential direction, φ...magnet end surface angle

Claims

1. A rotor manufacturing apparatus for attaching a magnet to an outer peripheral surface of a rotor core extending in an axial direction about a central axis, comprising: A rotor core support portion that supports the rotor core; a magnet support mechanism that supports the magnet on the radially outer side of the rotor core, The magnet support mechanism includes: a pair of support members that face each other in a facing direction perpendicular to both the radial direction and the axial direction and that have the magnet disposed therebetween; a drive unit that moves the pair of support members toward and away from each other in the opposing direction, The pair of support members each have a support surface that faces each other in the opposing direction and contacts a circumferential end surface of the magnet, The pair of support surfaces are inclined in directions away from each other in the opposing direction as they move radially outward. Rotor manufacturing equipment.

2. the angle between both end faces of the magnet in the circumferential direction is defined as a magnet end face angle, The angle between the pair of support surfaces is defined as a support surface angle, The support surface angle is maintained within ±10° with respect to the magnet end surface angle regardless of the distance between the pair of support members.

2. The rotor manufacturing apparatus according to claim 1.

3. an absolute value of a difference between a distance between the support surfaces at one end in the axial direction and a distance between the support surfaces at the other end in the axial direction is kept at 10 μm or less regardless of the distance between the pair of support members; 2. The rotor manufacturing apparatus according to claim 1.

4. a pair of contact plate portions located on both sides in the axial direction of the magnet supported by the magnet support mechanism; The pair of contact plate portions each have a contact surface that faces each other and is perpendicular to the axial direction.

2. The rotor manufacturing apparatus according to claim 1.

5. The magnet support mechanism has an adjustment unit that changes the radial distance of the pair of support members relative to the central axis.

2. The rotor manufacturing apparatus according to claim 1.

6. a pressure mechanism for pressing the magnet supported by the magnet support mechanism against the pair of support surfaces, 2. The rotor manufacturing apparatus according to claim 1.

7. The drive unit moves the pair of support members in opposite directions along the opposing direction at the same speed.

2. The rotor manufacturing apparatus according to claim 1.

8. A manufacturing method of a rotor in which a magnet is attached to an outer peripheral surface of a rotor core extending in an axial direction about a central axis, comprising the steps of: A direction perpendicular to both the radial direction and the axial direction of the central axis is defined as an opposing direction, a magnet support mechanism having a pair of support surfaces each inclined in a direction away from each other in the opposing direction as the support surfaces move outward in the radial direction, The magnet is supported by contacting circumferential end faces of the magnet with the pair of support surfaces, respectively; The pair of support surfaces are spaced apart from each other in the opposing direction, thereby moving the magnets inward in the radial direction and attaching them to the outer circumferential surface of the rotor core. A method for manufacturing a rotor.

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