Rotor, rotary electric machine, and method for manufacturing rotor and rotary electric machine

Abstract

To provide a rotor for effectively utilizing magnetic flux by suppressing reduction in a portion bearing a magnetic path in a rotor iron core when a gap is provided between rotor iron core plates of a rotor of an IPM structure.SOLUTION: A rotor 20 includes: a main shaft 30 serving as a rotating shaft; a rotor core 40 disposed radially outside the main shaft 30; and a magnet 50 disposed inside the rotor core 40 and having a magnetic pole surface 51. The rotor core 40 has a configuration in which a plurality of rotor core plates 60 are stacked with a gap provided in a shaft direction. The rotor core plate 60 is formed with a magnet hole 70 in which the magnet 50 is disposed, and a first protrusion 81 that is provided along the magnetic pole surface 51 of the magnet 50 and protrudes in the shaft direction at an end portion of the magnet hole 70 on a side where the magnetic pole surface 51 of the magnet 50 is disposed.SELECTED DRAWING: Figure 3

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 are two known rotor structures for rotating electrical machines: an Interior Permanent Magnet (IPM) structure in which multiple magnets are arranged inside the rotor core, and a Surface Permanent Magnet (SPM) structure in which magnets are arranged on the outer peripheral surface of the rotor core. The rotor core is composed of multiple rotor core plates stacked in the axial direction of the main shaft.

[0003] Some rotors with SPM structure use a reduced number of rotor core plates to reduce material costs and weight. For example, in Patent Document 1, the rotor core plates have protrusions that come into axial contact with the rotor core plates facing each other in the axial direction, and are arranged so that a gap is provided between the rotor core plates facing each other in the axial direction, which allows the number of rotor core plates to be reduced. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2019-165618 A Summary of the Invention [Problem to be solved by the invention]

[0005] When the method of Patent Document 1 is applied to a rotor with an IPM structure, i.e., when gaps are provided between the rotor core plates, the portion of the rotor core that carries the magnetic path is reduced, resulting in the problem that the magnetic flux cannot be utilized effectively.

[0006] The present disclosure has been made to solve the problems described above, and aims to provide a rotor and a rotating electric machine that can effectively utilize magnetic flux by suppressing the reduction of the portion of the rotor core that carries the magnetic path when gaps are provided between the rotor core plates of an IPM structure rotor, as well as a manufacturing method for the rotor and the rotating electric machine. [Means for solving the problem]

[0007] The rotor according to the present disclosure includes a main shaft serving as a rotating shaft, a rotor core disposed radially outward of the main shaft, and a magnet disposed inside the rotor core and having a magnetic pole surface. The rotor core is configured such that a plurality of rotor core plates are stacked with gaps provided in the axial direction, and the rotor core plate is formed with a magnet hole in which the magnet is disposed, and a first protrusion provided along the magnetic pole surface of the magnet at the end of the magnet hole on the side where the magnetic pole surface of the magnet is disposed and protruding in the axial direction.

[0008] The rotor according to the present disclosure includes a main shaft serving as a rotating shaft, an inner rotor core arranged radially outward of the main shaft, a magnet arranged radially outward of the inner rotor core and having a pole surface, and an outer rotor core arranged radially outward of the magnet. A plurality of structures formed of the magnets arranged radially outward of the inner rotor core and the outer rotor core are arranged circumferentially about the main shaft, and a gap is provided between the circumferential end faces of adjacent structures. The inner rotor core is configured such that a plurality of inner rotor core plates are stacked with gaps in the axial direction, and the outer rotor core is configured such that a plurality of outer rotor core plates are stacked with gaps in the axial direction, and at least one of the inner rotor core plates and the outer rotor core plate has a third convex portion formed along the pole surface of the magnet at an end on the side where the pole surface of the magnet is arranged and protruding in the axial direction.

[0009] A rotating electric machine according to the present disclosure includes any one of the rotors described above, and a stator disposed radially opposite the rotor.

[0010] The manufacturing method of a rotor according to the present disclosure includes a forming process for forming, in a rotor core plate, a magnet hole in which a magnet having a magnetic pole surface is arranged, and a first convex portion that is provided along the magnetic pole surface of the magnet at the end of the magnet hole on the side where the magnetic pole surface of the magnet is arranged and protrudes in the axial direction; a stacking process for stacking a plurality of rotor core plates with gaps between adjacent rotor core plates in the axial direction to form a rotor core; a joining process for placing a main shaft that serves as the rotating shaft and magnets inside the rotor core and joining the main shaft, magnets, and rotor core; and a magnetizing process for imparting magnetic force to the magnets.

[0011] A manufacturing method for a rotor according to the present disclosure is a manufacturing method for a rotor including a main shaft which is a rotating shaft, an inner rotor core arranged radially outward of the main shaft, a magnet arranged radially outward of the inner rotor core and having a pole face, and an outer rotor core arranged radially outward of the magnet, the manufacturing method including the steps of forming a third convex portion which is provided along the pole face of the magnet and protrudes in the axial direction on at least one of the inner rotor core plate forming the inner rotor core and the outer rotor core plate forming the outer rotor core, at an end on a side where the pole face of the magnet is arranged; The method includes a first lamination process in which the core plates are stacked with gaps between axially adjacent inner rotor core plates to form the inner rotor core, a second lamination process in which the outer rotor core plates are stacked with gaps between axially adjacent outer rotor core plates to form the outer rotor core, a joining process in which a main shaft which serves as the rotating shaft is disposed inside the inner rotor core, magnets are disposed radially outside the inner rotor core, the outer rotor core is disposed radially outside the magnets, and the main shaft, magnets, inner rotor core, and outer rotor core are joined together, and a magnetization process in which a magnetic force is imparted to the magnets.

[0012] A method for manufacturing a rotating electric machine according to the present disclosure includes a stator arrangement step of arranging a stator radially opposite the rotor, using a rotor manufactured by any one of the above-described rotor manufacturing methods. Effect of the Invention

[0013] According to the rotor and rotating electric machine of the present disclosure, when gaps are provided between the rotor core plates of a rotor with an IPM structure, the magnetic flux can be effectively utilized by suppressing the reduction of the portion of the rotor core that is responsible for the magnetic path. [Brief description of the drawings]

[0014] [Figure 1] 1 is a plan view showing a rotating electric machine according to a first embodiment of the present disclosure. [Diagram 2] FIG. 2 is a side view showing a rotor according to the first embodiment of the present disclosure. [Diagram 3] 1 is a cross-sectional view showing a rotor according to a first embodiment of the present disclosure. [Figure 4] 1 is a cross-sectional view showing a rotor according to a first embodiment of the present disclosure. [Diagram 5] 1 is a cross-sectional view showing a first modified example of a rotor according to a first embodiment of the present disclosure. [Figure 6] 1 is a cross-sectional view showing a first modified example of a rotor according to a first embodiment of the present disclosure. [Figure 7] 1 is a cross-sectional view showing a second modified example of the rotor according to the first embodiment of the present disclosure. [Figure 8] 11 is a cross-sectional view showing a third modified example of the rotor according to the first embodiment of the present disclosure. FIG. [Figure 9] 11 is a cross-sectional view showing a fourth modified example of the rotor according to the first embodiment of the present disclosure. FIG. [Figure 10] 11 is a cross-sectional view showing a fourth modified example of the rotor according to the first embodiment of the present disclosure. FIG. [Figure 11] 5 is a flowchart showing a method for manufacturing the rotor according to the first embodiment of the present disclosure. [Figure 12] 5A to 5C are schematic diagrams illustrating a manufacturing process for the rotor according to the first embodiment of the present disclosure. [Figure 13] 5A to 5C are schematic diagrams illustrating a manufacturing process for the rotor according to the first embodiment of the present disclosure. [Figure 14] FIG. 2 is a schematic diagram showing magnetic flux of a rotor according to the first embodiment of the present disclosure. [Figure 15] FIG. 4 is a schematic diagram showing magnetic flux in a rotor according to a first comparative example to the first embodiment of the present disclosure. [Figure 16] FIG. 2 is a schematic diagram showing magnetic flux of a rotor according to the first embodiment of the present disclosure. [Figure 17] FIG. 11 is a cross-sectional view showing a rotor according to a second embodiment of the present disclosure. [Figure 18] FIG. 11 is a cross-sectional view showing a rotor according to a second embodiment of the present disclosure. [Figure 19] 11 is a flowchart showing a method for manufacturing a rotor according to a second embodiment of the present disclosure. [Figure 20] FIG. 11 is a schematic diagram showing magnetic flux in a rotor according to embodiment 2 of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, an example of a rotor and a rotating electric machine according to the present disclosure, and a manufacturing method of the rotor and the rotating electric machine will be described with reference to the drawings. In the following drawings, the same or corresponding parts are given the same reference numerals, and the description thereof will not be repeated. In addition, in the following description, when axial, radial, and circumferential directions are mentioned, unless otherwise specified, they refer to the rotational axis direction, radial direction, and circumferential direction of the rotational axis in a cylindrical coordinate system centered on the rotational axis of the rotor. Furthermore, the number of magnetic poles, the number of permanent magnets used, the number of winding poles, etc. are merely examples, and may be increased or decreased as desired and are not limited to those used in the description.

[0016] Embodiment 1 A first embodiment of the present disclosure is a rotor including a main shaft serving as a rotating shaft, a rotor core arranged radially outward of the main shaft, and a magnet arranged inside the rotor core and having a magnetic pole surface, the rotor core being configured such that a plurality of rotor core plates are stacked with gaps in the axial direction, and the rotor core plate has a magnet hole in which the magnet is arranged, and a first convex portion arranged along the magnetic pole surface of the magnet and protruding in the axial direction at the end of the magnet hole on the side where the magnetic pole surface of the magnet is arranged. The first embodiment of the present disclosure also relates to a rotating electric machine using this rotor. The first embodiment of the present disclosure also relates to a manufacturing method of the rotor and the rotating electric machine.

[0017] <Configuration of First Embodiment> The configuration of a rotating electric machine 10 according to a first embodiment of the present disclosure will be described with reference to Fig. 1. Fig. 1 is a plan view of the overall structure of the rotating electric machine 10 as viewed from an axial end face of the rotating electric machine 10. In Fig. 1, in order to clarify the directions described above, the direction perpendicular to the rotation axis (the up-down direction in Fig. 1) is described as the radial direction (R), and the direction along the rotation direction centered on the rotation axis is described as the circumferential direction (P).

[0018] 1, a rotating electric machine 10 includes a stator 1 and a rotor 20. The stator 1 is disposed radially outwardly of the rotor 20 so as to face the rotor 20 with an air gap 2 therebetween.

[0019] Stator 1 includes teeth 3 that protrude in the radial direction from a yoke that is connected to form a circle at the outermost circumference, by the number of slots, and stator windings 4 made of copper wire wound around teeth 3 with an insulating layer (not shown) sandwiched therebetween. Rotor 20 is integrated with main shaft 30, and each component of rotor 20 will be described with reference to Figs. 2, 3, and 4.

[0020] The stator 1 and the rotor 20 exchange magnetic flux through an air gap 2, which is a tiny air layer. Specifically, a rotating magnetic field formed in the stator 1 by energizing the stator windings 4 generates torque in the rotor 20. As a result, the stator 1 and the rotor 20 function as a rotating electric machine 10.

[0021] Next, the configuration of the rotor 20 according to the first embodiment of the present disclosure will be described with reference to Figs. 2, 3, and 4. Fig. 2 is a side view showing the rotor 20 of the rotating electric machine 10. Fig. 3 is a cross-sectional view taken along line AA in Fig. 2, illustrating magnetic poles. Fig. 4 is a cross-sectional view taken along line BB in Fig. 2. In Figs. 2, 3, and 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 onward, the axial direction (X), radial direction (R), and circumferential direction (P) are also shown as appropriate in order to clarify the directions.

[0022] 2, 3, and 4, rotor 20 includes a main shaft 30 which is the rotating shaft of rotating electric machine 10, a rotor core 40 arranged radially outside of main shaft 30, and a magnet 50 arranged inside rotor core 40 and having a magnetic pole face 51. As shown in Fig. 2, rotor core 40 is configured such that a plurality of rotor core plates 60 are stacked with gaps provided in the axial direction.

[0023] The main shaft 30 is connected to the rotor core 40 directly or via resin (not shown). The radial thickness of the rotor core 40 is set to a minimum length that ensures a magnetic path that is not saturated with the magnetic flux generated by the magnet 50.

[0024] As shown in Figures 3 and 4, magnets 50 having magnetic pole faces are arranged inside rotor core 40. Magnets 50 are arranged at predetermined intervals in the circumferential direction of main shaft 30, the number of magnets being equal to the number of poles of rotor 20. Figures 3 and 4 show a rotor in which six magnets 50 are arranged, as an example. However, the number of poles of the rotor may be different.

[0025] 3 and 4, the magnetic pole face 51 of the magnet 50 is a surface perpendicular to the radial direction. Note that it is desirable for the magnet 50 to have a magnetic force that does not saturate the rotor core plate 60, and an example of the magnet material is ferrite.

[0026] Furthermore, the arrangement of the magnets 50 is not limited to the arrangement shown in Figures 3 and 4, and may be a spoke-like arrangement in which the magnets 50 are arranged radially, a three-sided concentrated arrangement in which another magnet 50 is arranged between radially arranged magnets 50, or a V-shaped arrangement in which two magnets 50 are arranged in a V shape.

[0027] 3 and 4, magnet holes 70 in which magnets 50 are placed are formed in rotor core plate 60. The diameter of magnet holes 70 is desirably the same as the diameter of magnets 50. If the diameter of magnet holes 70 is larger than the diameter of magnets 50, the gaps between the ends of magnet holes 70 and magnets 50 may be filled with resin (not shown) or a magnetic material (not shown) to fix magnets 50 in place.

[0028] Furthermore, rotor core plate 60 is provided with a first convex portion 81 that is provided along pole surface 51 of magnet 50 and protrudes in the axial direction at the end of magnet hole 70 on the side where pole surface 51 of magnet 50 is arranged. First convex portion 81 includes first convex portion 81a that is provided along pole surface 51 of magnet 50 at end 70a on the radially outer side of magnet hole 70 as shown in Figs. 3 and 4. First convex portion 81a is desirably provided along the entire surface of pole surface 51 of magnet 50. Furthermore, first convex portion 81a may be provided along a portion of pole surface 51 of magnet 50.

[0029] It is sufficient that first convex portion 81 is provided along pole surface 51 of magnet 50 at the end of magnet hole 70 on the side where pole surface 51 of magnet 50 is arranged. Rotor 21 in Modification 1, in which first convex portion 81 is formed at a different position, will be described with reference to Figures 5 and 6. Figure 5 is a cross-sectional view of rotor 21 corresponding to line segment AA shown in Figure 2, and Figure 6 is a cross-sectional view of rotor 21 corresponding to line segment BB shown in Figure 2.

[0030] 5 and 6, the first convex portion 81 of the rotor 21 in the first modification includes, in addition to the first convex portion 81a, a first convex portion 81b provided along the pole surface 51 of the magnet 50 at the radially inner end 70b where the pole surface 51 of the magnet 50 is disposed in the magnet hole 70. The first convex portion 81b is desirably provided along the entire surface of the pole surface 51 of the magnet 50. The first convex portion 81b may also be provided along a part of the pole surface 51 of the magnet 50. Note that, in FIGS. 5 and 6, the rotor 21 includes two first convex portions 81 provided at different positions, the first convex portion 81a and the first convex portion 81b, but may include only the first convex portion 81b.

[0031] First convex portion 81a and first convex portion 81b are provided along pole surface 51 of magnet 50 at the end of magnet hole 70 on the side where pole surface 51 of magnet 50 is arranged, and are desirably provided so as to contact pole surface 51 of magnet 50. Rotors 22 and 23 in which first convex portion 81 is provided so as to contact the pole surface of magnet 50 will be described with reference to Figs. 7 and 8. Fig. 7 shows rotor 22 in Modification 2. Fig. 7 is a cross-sectional view of rotor 22 corresponding to line segment AA shown in Fig. 2. Fig. 8 shows rotor 23 in Modification 3. Fig. 8 is a cross-sectional view of rotor 23 corresponding to line segment AA shown in Fig. 2.

[0032] Rotor 22 in Modification 2 shown in Fig. 7 is an example in which the diameter of magnet hole 70 is the same as the diameter of magnet 50. As shown in Fig. 7, when the diameter of magnet hole 70 is the same as the diameter of magnet 50, first convex portion 81a and first convex portion 81b contact pole surface 51 of magnet 50. Rotor 23 in Modification 3 shown in Fig. 8 is an example in which the diameter of magnet hole 70 is larger than the diameter of magnet 50. As shown in Fig. 8, when the diameter of magnet hole 70 is larger than the diameter of magnet 50, it is desirable to position magnet 50 radially outward so that pole surface 51 of magnet 50 contacts first convex portion 81a.

[0033] The first convex portion 81 contacts the axial end face of the rotor core plate 60 axially adjacent to the rotor core plate 60 on which the first convex portion 81 is formed, providing a gap between the axially adjacent rotor core plates.

[0034] Rotor core plate 60 may further include second protrusions 82 that are provided along the circumferential direction at positions on outer circumferential portion 60a of rotor core plate 60 facing pole face 51 of magnet 50 and protrude in the axial direction. Rotor 24 in modification 4 that includes second protrusions 82 will be described with reference to Figures 9 and 10. Figure 9 is a cross-sectional view of rotor 24 corresponding to line segment AA shown in Figure 2, and Figure 10 is a cross-sectional view of rotor 24 corresponding to line segment BB shown in Figure 2.

[0035] As shown in Figs. 9 and 10, the rotor 24 in the fourth modification further includes, in addition to the first convex portion 81a and the first convex portion 81b, a second convex portion 82 that is provided along the circumferential direction at a position of the outer circumferential portion 60a of the rotor core plate 60 that faces the magnetic pole surface 51 of the magnet 50 and protrudes in the axial direction. The second convex portion 82 may be provided on the entire circumference of the outer circumferential portion 60a of the rotor core plate 60. The second convex portion 82 may be provided only on a portion of the outer circumferential portion 60a of the rotor core plate 60 that faces the magnetic pole surface 51 of the magnet 50. In Figs. 9 and 10, the rotor 24 includes two first convex portions 81 and a second convex portion 82 that are provided at different positions of the first convex portion 81a and the first convex portion 81b, but may include the first convex portion 81 and the second convex portion 82 on either the first convex portion 81a or the first convex portion 81b.

[0036] The second convex portion 82 contacts the axial end face of the rotor core plate 60 axially adjacent to the rotor core plate 60 on which the second convex portion 82 is formed, providing a gap between the axially adjacent rotor core plates.

[0037] The rotor core plate 60 is a thin plate made of a magnetic material with high magnetic permeability, for example, an iron-based metal.

[0038] In the description of rotors 20, 21, 22, 23, 24 according to embodiment 1, cylindrical rotors 20, 21, 22, 23, 24 have been exemplified, but as long as the configuration of embodiment 1 is followed, the radial cross-sectional shape of rotor core 40 is not limited to a perfect circle. For example, rotor core plate 60 located between circumferentially adjacent magnets 50 may have a radial length shorter than the outermost diameter of rotor core plate 60, and rotor core plate 60 located radially outside magnets 50 may have a petal shape with a curvature larger than the curvature of the outermost circumference of rotors 20, 21, 22, 23, 24.

[0039] <Manufacturing Method of First Embodiment> A manufacturing method of rotors 20, 21, 22, 23, 24 according to the first embodiment of the present disclosure will be described with reference to Figs. 11, 12, and 13. Fig. 11 is a flowchart showing the manufacturing method of rotors 20, 21, 22, 23, 24. Fig. 12 is a perspective view of rotor core plate 60, showing the forming process of rotor core plate 60. Fig. 12(a) shows rotor core plate 60 before first convex portion 81a is provided, and Fig. 12(b) shows rotor core plate 60 after first convex portion 81a is provided. Fig. 13 is a perspective view of rotor core 40, showing the lamination process of rotor core plate 60.

[0040] As shown in FIG. 11, the manufacturing process for rotors 20, 21, 22, 23, and 24 includes step 01 (S01) to step 04 (S04) which will be described below.

[0041] In the forming process of step 01 (S01), a magnet hole 70 in which a magnet 50 having a magnetic pole surface 51 is arranged is formed in the rotor core plate 60, and a first convex portion 81 is formed along the magnetic pole surface 51 of the magnet 50 at the end of the magnet hole 70 on the side where the magnetic pole surface 51 of the magnet 50 is arranged, and protrudes in the axial direction.

[0042] In the forming step S01, a procedure for forming a first convex portion 81a, which is one of the first convex portions 81, will be described with reference to FIG. 12. First, as shown in FIG. 12(a), the rotor core plate 60 is punched to form a magnet hole 70 and a protruding portion 60b protruding radially inward from a radially outer end portion 70a of the magnet hole 70. Next, as shown in FIG. 12(b), the protruding portion 60b formed in the rotor core plate 60 is bent at a right angle (90°) axially outward to form a first convex portion 81a at the radially outer end portion 70a of the magnet hole 70. Here, the radially outer end portion 70a of the magnet hole 70 is the side where the magnetic pole surface 51 of the magnet 50 is arranged. The punching process shown in FIG. 12(a) and the bending process shown in FIG. 12(b) may be performed simultaneously using a die.

[0043] When forming the first convex portion 81b and the second convex portion 82, the forming step S01 is basically the same as the procedure for forming the first convex portion 81a. When providing the second convex portion 82 on the entire circumference of the outer periphery 60a of the rotor core plate 60, the rotor core plate 60 is first punched to form the magnet holes 70 and protruding portions (not shown) protruding radially outward from the outer periphery 60a of the rotor core plate 60. A plurality of protruding portions protruding radially outward from the outer periphery 60a of the rotor core plate 60 are provided circumferentially on the outer periphery 60a of the rotor core plate 60. The plurality of protruding portions protruding radially outward from the outer periphery 60a of the rotor core plate 60 are formed so that the total circumferential length of the radially outer ends of the protruding portions is the same as the length of the outer periphery 60a of the rotor core plate 60. Next, second convex portions 82 are formed by bending a plurality of protruding portions formed on rotor core plate 60 and protruding radially outward from outer periphery 60a of rotor core plate 60.

[0044] The first convex portion 81 and the second convex portion 82 may be formed by adhering or welding a block that will become the first convex portion 81 and the second convex portion 82 to the rotor core plate 60. The block is made of a magnetic material, and is desirably made of the same material as the rotor core plate 60. According to the method of adhering or welding the block, there is no need to form a protrusion during punching, and the rotor core plate 60 that has been punched into a simple shape is adhered or welded to the block, making it easy to change the width of the first convex portion 81, etc.

[0045] In the lamination process of step 02 (S02), the rotor core 40 is formed by laminating the multiple rotor core plates 60 that have undergone the formation process S01 with gaps provided between adjacent rotor core plates 60 in the axial direction.

[0046] A procedure for stacking rotor core plates 60 on which a first convex portion 81a, which is one of the first convex portions 81, is formed in the stacking step S02 will be described with reference to Fig. 13. The first convex portion 81a is formed on the rotor core plate 60 that has undergone the forming step S01. The first convex portion 81a contacts the axial end face of the rotor core plate 60 that is axially adjacent to the rotor core plate 60 on which the first convex portion 81a is formed. Therefore, the first convex portion 81a formed on the rotor core plate 60 allows the rotor core plates 60 to be stacked with a gap between adjacent rotor core plates 60 in the axial direction.

[0047] When stacking rotor core plates 60 on which first convex portions 81b and second convex portions 82 are formed, the lamination step S02 is the same as the procedure for stacking rotor core plates 60 on which first convex portions 81a are formed. The first convex portions 81 and second convex portions 82 including the first convex portions 81a and 81b formed on the rotor core plates 60 enable stacking with a gap between adjacent rotor core plates 60 in the axial direction.

[0048] In the lamination process S02, it is necessary to position and stack the rotor core plates 60 in the radial and circumferential directions so that the positions of the magnet holes 70 formed in the rotor core plates 60 overlap. For positioning, for example, a die (not shown) equipped with positioning pins (not shown) may be used. The positioning pins are arranged, for example, in positions contacting the radial inside of the magnet holes 70 formed in the rotor core plates 60. The rotor core plates 60 are positioned so that the positioning pins of the die pass through the magnet holes 70, and are stacked while being positioned in the radial and circumferential directions.

[0049] In the joining process of step 03 (S03), the main shaft 30, which becomes the rotating shaft, and the magnets 50 are placed inside the rotor core 40, and the main shaft 30, the magnets 50, and the rotor core 40 are joined together. Methods for joining the main shaft 30 and the rotor core 40 include, for example, shrink fitting, cold fitting, press fitting, welding, and bonding. Methods for fixing the magnets 50 include, for example, bonding, or placing an end plate (not shown) made of a non-magnetic material on the axial end face of the magnet hole 70 of the rotor core 40.

[0050] As another joining method, the main shaft 30, the magnet 50, and the rotor core 40 can be joined by placing them in a molding die and injecting resin into the die. This joining method using resin is preferable because it allows the main shaft 30, the magnet 50, and the rotor core 40 to be joined together in one step.

[0051] In the case of the resin-based coupling method, the rotor core 40 is obtained by laminating rotor core plates 60 in which the diameter of the main shaft hole (not shown) of the rotor core 40 in which the main shaft 30 is placed is larger than the diameter of the main shaft 30, and a gap is provided between the main shaft 30 and the rotor core 40, and the main shaft 30 and the rotor core 40 can be coupled with resin. When the resin-based coupling method is used, the radial thickness of the rotor core 40 up to the magnet 50 is set to a minimum length that ensures a magnetic path that is not saturated with the magnetic flux generated by the magnet 50. According to the resin-based coupling method, the material used for the rotor core 40 can be reduced by the difference between the diameter of the main shaft 30 and the diameter of the main shaft hole, thereby reducing material costs. In addition, according to the resin-based coupling method, the main shaft 30 and the rotor core 40 are not directly coupled to each other but are coupled to each other via resin, so that the effect of preventing electrolytic corrosion can be obtained.

[0052] Incidentally, by providing a mating portion (not shown) that can be mated with the main shaft 30 and the rotor core plate 60, the laminating step S02 and part of the joining step S03 may be performed together. By providing a mating protrusion (not shown) on the main shaft 30 and a mating recess (not shown) on the rotor core plate 60, the rotor core plate 60 can be stacked and joined to the main shaft 30 while positioning the rotor core plate 60 in the radial and circumferential directions. Here, the main shaft 30 may be provided with a mating recess, and the rotor core plate 60 may be provided with a mating protrusion. Furthermore, by using the main shaft 30 and the rotor core plates 60 having a mating portion, the rotor core plates 60 can be stacked with a gap between adjacent rotor core plates 60 in the axial direction, without using the first protrusions 81.

[0053] In the magnetization process of step 04 (S04), a magnetization device is used to impart magnetic force to magnet 50. In this way, rotors 20, 21, 22, 23, and 24 in the present embodiment 1 can be obtained. Rotors 20, 21, 22, 23, and 24 manufactured by such a manufacturing method can suppress reduction of the portion of rotor core 40 that carries the magnetic path, and can effectively utilize the magnetic flux.

[0054] The rotating electric machine 10 can be manufactured by using any one of the rotors 20, 21, 22, 23, 24 manufactured using the manufacturing method for the rotors 20, 21, 22, 23, 24 described in the flowchart of Figure 11, and by providing a stator arrangement process in which a stator 1 is arranged radially outside any one of the rotors 20, 21, 22, 23, 24 via an air gap.

[0055] <Effects of the First Embodiment> Next, the operation and effect of the rotor 20, 21, 22, 23, 24 and the rotating electric machine 10 according to the first embodiment of the present disclosure will be described with reference to FIG. 14, FIG. 15, and FIG. 16. FIG. 14 and FIG. 16 are schematic diagrams showing the magnetic flux in the rotor 22 according to the first embodiment of the present disclosure, and FIG. 15 is a schematic diagram showing the magnetic flux in the rotor 300 of the first comparative example. The rotor 300 of the first comparative example is different from the rotors 20, 21, 22, 23, 24 according to the first embodiment of the present disclosure in that the first convex portion 81 is not formed. FIG. 14 is a schematic cross-sectional view of the rotor 24. FIG. 14 is a cross-sectional view corresponding to the line segment AA shown in FIG. 2. In FIG. 14, the magnetic flux is indicated by a broken line. FIG. 15 is a cross-sectional view corresponding to the broken line portion shown in FIG. 2. In FIG. 15, the magnetic flux is indicated by an outline arrow. Fig. 16 is a schematic cross-sectional view of rotor 24. Fig. 16 is a cross-sectional view corresponding to the dashed line portion shown in Fig. 2. In Fig. 16, magnetic flux is indicated by white arrows. Note that in Figs. 14, 15, and 16, the axial direction (X), radial direction (R), and circumferential direction (P) are indicated.

[0056] First, the operating principle of the rotating electric machine 10 will be described. The rotor 22 equipped with the magnets 50 generates magnetic flux from the pole faces 51 of the magnets 50, forming a magnetic field by the magnets 50. When the stator windings 4 of the stator 1 are energized, a rotating magnetic field is generated by the current. The magnetic field by the magnets 50 and the rotating magnetic field by the current interact with each other, generating torque in the rotor 22. That is, when the rotating electric machine 10 is driven, the stator 1 and the rotor 22 exchange magnetic flux. Focusing on the rotor 22, magnetic flux is exchanged between the magnets 50 and the stator 1 arranged radially outward of the rotor 22, and between the magnets 50 adjacent in the circumferential direction.

[0057] As shown in FIG. 14, the magnetic flux in the rotor 22 is generated from one magnetic pole face 51 of the magnet 50, passes through the rotor core plate 60, the air gap 2 between the rotor core 40 and the stator 1, the stator 1, and the air gap 2 between the rotor core 40 and the stator 1, returns to the rotor core plate 60 again, and heads toward the other magnetic pole face 51 of the adjacent magnet 50. That is, the rotor core 40 serves as a magnetic path between the stator 1 and the magnet 50, with the air gap 2 sandwiched between them on the radial outside. Also, the magnetic flux in the rotor 22 is generated from one magnetic pole face 51 of the magnet 50, passes through the rotor core plate 60, and heads toward the other magnetic pole face 51 of the adjacent magnet 50. That is, the rotor core 40 serves as a magnetic path between the magnets 50 adjacent in the circumferential direction.

[0058] The rotor core 40, which carries the magnetic path, is made of a material with high magnetic permeability, allowing magnetic flux to pass easily. Air or non-magnetic materials have a lower magnetic permeability than the rotor core 40, and magnetic flux leakage occurs when air or non-magnetic materials are present in the magnetic path. For this reason, the more magnetic flux passing through the rotor core 40 is increased, the more effectively the magnetic flux can be utilized.

[0059] Next, the effects of the rotors 20, 21, 22, 23, and 24 in the present disclosure will be described using the rotor 22 of the first embodiment and the rotor 300 of the first comparative example. The rotor 300 shown as the first comparative example has a structure in which the rotor core plates 60 on which the first protrusions 81 are not formed are stacked with gaps in the axial direction, as shown in FIG. 15. In this structure, the portion carrying the magnetic path in the rotor core 40 is reduced by the gaps in the axial direction compared to a structure in which the rotor core plates 60 are stacked without gaps in the axial direction. The gaps in the axial direction are made of air or resin, which is a nonmagnetic material, so that the magnetic flux passing through the air or nonmagnetic material increases. Therefore, in the rotor 300 in which the rotor core plates 60 are stacked with gaps in the axial direction, magnetic flux leakage is more likely to occur than in a structure in which the rotor core plates 60 are stacked without gaps in the axial direction, and the magnetic flux of the rotor 300 cannot be effectively utilized.

[0060] In contrast, in the rotor 24 according to the first embodiment of the present disclosure, as shown in FIG. 16, a first convex portion 81 is formed at the end of the magnet hole 70 on the side where the pole face 51 of the magnet 50 is arranged, along the pole face 51 of the magnet 50, and protrudes in the axial direction. The first convex portion 81 is formed at the position where the magnetic flux passes, and the first convex portion 81 becomes a magnetic path, thereby suppressing the reduction of the portion of the rotor core 40 that serves as the magnetic path between the stator 1 and the magnet 50. For example, the first convex portion 81a is provided at the radially outer end 70a where the pole face 51 of the magnet 50 is arranged in the magnet hole 70, and therefore the reduction of the portion of the rotor core 40 that serves as the magnetic path between the stator 1 and the magnet 50 can be suppressed. The first convex portion 81b is provided at the radially inner end 70b where the pole face 51 of the magnet 50 is arranged in the magnet hole 70, and therefore the reduction of the portion of the rotor core 40 that serves as the magnetic path between the magnets 50 adjacent in the circumferential direction can be suppressed. As a result of suppressing the reduction in the portion that carries the magnetic path, in rotor 300 of comparison example 1, a portion of the magnetic flux that passed through the air or non-magnetic material is taken in by first convex portion 81 and passes through the inside of rotor core plate 60. In this way, in rotors 20, 21, 22, 23, and 24 of embodiment 1 of the present disclosure, the first convex portion 81 is provided along the pole face 51 of magnet 50 at the end of the magnet hole 70 on the side where pole face 51 of magnet 50 is arranged, and therefore, compared to rotor 300 of comparative example 1, leakage of the magnetic flux generated by magnet 50 due to air or non-magnetic material is suppressed, and the magnetic flux can be effectively utilized.

[0061] It is desirable that first convex portion 81 be provided at the end of magnet hole 70 on the side where both of the two magnetic pole faces 51 of magnet 50 are arranged. That is, as shown in Fig. 14, first convex portion 81 is provided along magnetic pole face 51 of magnet 50 at radially outer end 70a and radially inner end 70b where magnetic pole face 51 of magnet 50 is arranged in magnet hole 70, thereby suppressing reduction of the portion carrying the magnetic path in rotor core 40 and enabling more effective use of magnetic flux.

[0062] The end of magnet hole 70 on the side where pole face 51 of magnet 50 is arranged, where first convex portion 81 is formed, is the position on rotor core plate 60 closest to pole face 51 of magnet 50. The closer the position where first convex portion 81 is formed to pole face 51 of magnet 50, the smaller the gap between first convex portion 81 and pole face 51 of magnet 50 and the less magnetic flux passes through the air or non-magnetic material, and therefore first convex portion 81 is formed at the end of magnet hole 70 on the side where pole face 51 of magnet 50 is arranged.

[0063] It is desirable that the first convex portion 81 is formed so as to contact the magnetic pole surface 51 of the magnet 50. By forming the first convex portion 81 so as to contact the magnetic pole surface 51 of the magnet 50, the gap between the first convex portion 81 and the magnetic pole surface 51 of the magnet 50 can be minimized, thereby further suppressing magnetic flux leakage and enabling effective use of the magnetic flux.

[0064] As shown in FIG. 16, by further providing the second convex portion 82, it is possible to further suppress the magnetic flux leakage and effectively utilize the magnetic flux. The second convex portion 82 is provided along the circumferential direction at a position facing the pole surface 51 of the magnet 50 in the outer peripheral portion 60a of the rotor core plate 60, and therefore it is possible to suppress the reduction of the portion of the rotor core 40 that carries the magnetic path between the stator 1 and the magnet 50. As a result, in the rotor 300 of Comparative Example 1, a part of the magnetic flux between the stator 1 and the magnet 50 that passed through the air or non-magnetic material is taken in by the second convex portion 82 and passes through the inside of the rotor core plate 60. That is, by further providing the second convex portion 82, leakage of the magnetic flux passing between the stator 1 and the magnet 50 in the air or non-magnetic material is suppressed compared to the rotor 300 of Comparative Example 1, and the magnetic flux can be effectively utilized.

[0065] By making effective use of the magnetic flux, for example, it is possible to suppress a decrease in torque. When magnetic flux leakage occurs in rotors 20, 21, 22, 23, and 24, the strength of the magnetic field produced by magnet 50 is weakened, and the torque generated by the interaction with the rotating magnetic field is reduced. According to rotors 20, 21, 22, 23, and 24 according to the first embodiment of the present disclosure, first convex portion 81 and second convex portion 82 suppress magnetic flux leakage and make effective use of magnetic flux, so that it is possible to suppress a weakening of the magnetic field produced by magnet 50 and obtain sufficient torque. Furthermore, by making effective use of the magnetic flux, it is possible to suppress a decrease in the power efficiency of the rotating electric machine 10. When magnetic flux leakage occurs in the rotors 20, 21, 22, 23, 24, the torque decreases by an amount corresponding to the leaked magnetic flux, and therefore it is necessary to strengthen the applied current. According to the rotors 20, 21, 22, 23, 24 according to the first embodiment of the present disclosure, the first convex portion 81 and the second convex portion 82 suppress magnetic flux leakage and make effective use of the magnetic flux, so that it is possible to suppress a decrease in torque and a decrease in power efficiency.

[0066] Furthermore, according to rotors 20, 21, 22, 23, and 24 according to embodiment 1 of the present disclosure, first convex portion 81a and first convex portion 81b effectively utilize the magnetic flux near magnet 50, thereby improving the magnetization effect in magnetization step S04, which is one of the manufacturing steps. First convex portion 81a and first convex portion 81b, which have high magnetic permeability, reduce the magnetic resistance near magnet 50, making it easier for magnetic flux to pass through magnet 50 during magnetization, thereby improving the magnetization effect.

[0067] When the first convex portion 81 contacts the axial end face of the rotor core plate 60 axially adjacent to the rotor core plate 60 on which the first convex portion 81 is formed, the first convex portion 81 not only serves to suppress reduction of the portion of the rotor core 40 that provides the magnetic path, but also serves to provide a gap between the axially adjacent rotor core plates 60. The first convex portion 81 has a simple structure, making it possible to provide a gap between the axially adjacent rotor core plates 60, thereby reducing manufacturing costs.

[0068] As with the first convex portion 81, when the second convex portion 82 contacts the axial end face of the rotor core plate 60 adjacent to the rotor core plate 60 on which the second convex portion 82 is formed, the second convex portion 82 not only serves to suppress the reduction of the portion of the rotor core 40 that carries the magnetic path, but also serves to provide a gap between the rotor core plates 60 adjacent in the axial direction. The second convex portion 82, which has a simple structure, can provide a gap between the rotor core plates 60 adjacent in the axial direction, thereby reducing manufacturing costs. Furthermore, by forming the second convex portion 82 in addition to the first convex portion 81, a gap can be more stably provided between the rotor core plates 60 adjacent in the axial direction. Furthermore, when the second convex portion 82 contacts the axial end face of the rotor core plate 60 that is axially adjacent to the rotor core plate 60 on which the second convex portion 82 is formed, there is no need for the first convex portion 81 to play the role of creating a gap between the axially adjacent rotor core plates 60, and the second convex portion 82 can stably create a gap between the axially adjacent rotor core plates 60.

[0069] As described above, according to the rotors 20, 21, 22, 23, 24 and rotating electric machine 10 of embodiment 1 of the present disclosure, and the manufacturing method of the rotors 20, 21, 22, 23, 24 and rotating electric machine 10, the rotor core plate 60 is provided with a first convex portion 81 that is arranged along the pole face 51 of the magnet 50 and protrudes in the axial direction at the end portion on the side where the pole face 51 of the magnet 50 is arranged in the magnet hole 70. In this way, when a gap is provided between the rotor core plates 60 of the rotor 20 having an IPM structure, the reduction of the portion that carries the magnetic path in the rotor core 40 is suppressed, and the magnetic flux can be effectively utilized.

[0070] Furthermore, according to the rotors 20, 21, 22, 23, 24 and rotating electric machine 10 and the manufacturing method for the rotors 20, 21, 22, 23, 24 and rotating electric machine 10 relating to embodiment 1 of the present disclosure, the first convex portion 81 has a simple structure, making it possible to provide a gap between adjacent rotor core plates 60 in the axial direction, thereby reducing manufacturing costs.

[0071] Embodiment 2 In the first embodiment of the present disclosure, rotors 20, 21, 22, 23, and 24 have been described in which rotor core plates 60 on which first convex portions 81 are formed are stacked with gaps in the axial direction. In the rotor core plate 60 of the first embodiment, a bridge is formed between circumferentially adjacent magnets 50, and this bridge may cause magnetic flux to leak to the circumferentially adjacent magnets 50, preventing effective use of the magnetic flux of the magnets 50. In the second embodiment, a rotor having a bridgeless structure in which the rotor core is separated radially inside and outside the magnets in order to eliminate bridges between circumferentially adjacent magnets, and in which rotor core plates on which third convex portions 83 are formed are stacked with gaps in the axial direction, will be described. In the second embodiment, the same components as those in the first embodiment of the present disclosure are designated by the same reference numerals, and descriptions of the same or corresponding parts are omitted. Hereinafter, a rotor 220 according to the second embodiment will be described with reference to the drawings. The second embodiment of the present disclosure also relates to a rotating electric machine 210 using the rotor 220. The second embodiment of the present disclosure also relates to a manufacturing method of the rotor 220 and the rotating electric machine 210.

[0072] <Configuration of the Second Embodiment> The configuration of a rotating electric machine 210 according to a second embodiment of the present disclosure will be described with reference to Fig. 17 and Fig. 18. Fig. 17 is a cross-sectional view of rotor 220 corresponding to line segment AA shown in Fig. 2. Fig. 18 is a cross-sectional view of rotor 220 corresponding to line segment BB shown in Fig. 2. Note that in Figs. 17 and 18, the axial direction (X), radial direction (R), and circumferential direction (P) are indicated.

[0073] 17 and 18, rotor 220 includes main shaft 30 which is a rotating shaft, inner rotor core 241 arranged radially outward of main shaft 30, magnet 50 arranged radially outward of inner rotor core 241 and having magnetic pole face 51, and outer rotor core 242 arranged radially outward of magnet 50. Inner rotor core 241 and outer rotor core 242 are rotor core 40 of embodiment 1 separated radially inside and outside magnet 50.

[0074] Main shaft 30 is coupled to inner rotor core 241 directly or via resin (not shown). The radial thickness of inner rotor core 241 is set to a minimum length that ensures a magnetic path that is not saturated with the magnetic flux generated by magnet 50.

[0075] As shown in FIGS. 17 and 18, magnet 50 having magnetic pole surface 51 is arranged radially outside inner rotor core 241. Furthermore, outer rotor core 242 is arranged radially outside magnet 50. Magnet 50 and outer rotor core 242 arranged radially outside inner rotor core 241 are arranged as structure 90 at a predetermined interval in the circumferential direction with respect to main shaft 30, the number of poles of rotor 220. A gap is provided between the circumferential end faces of adjacent structures 90. This gap between the circumferential end faces of adjacent structures 90 corresponds to the portion where the bridge was formed in rotors 20, 21, 22, 23, and 24 of embodiment 1. The gap between the circumferential end faces of adjacent structures 90 may be filled with a non-magnetic material.

[0076] 17 and 18 show, as an example, a rotor in which six magnets 50 are arranged, although the number of poles of the rotor may be other numbers.

[0077] 17 and 18, the magnetic pole face 51 of the magnet 50 is a surface perpendicular to the radial direction. Note that the magnet 50 desirably has a magnetic force that does not saturate the rotor core plate 60, and an example of the magnet material is ferrite.

[0078] 3 and 4, two magnets 50 may be arranged in a V shape. The shapes of inner rotor core 241 and outer rotor core 242 may be changed according to the arrangement of magnets 50.

[0079] 17 and 18, magnet 50 is disposed between inner rotor core 241 and outer rotor core 242. It is desirable that radially outer end 241a of inner rotor core 241 and pole face 51 of magnet 50 are disposed in contact with radially inner end 242b of outer rotor core 242 and pole face 51 of magnet 50. When radially outer end 241a of inner rotor core 241 or radially inner end 242b of outer rotor core 242 is disposed with a gap between pole face 51 of magnet 50, the gap between radially outer end 241a of inner rotor core 241 or radially inner end 242b of outer rotor core 242 and magnet 50 may be filled with resin (not shown) or a magnetic material (not shown).

[0080] 18, inner rotor core 241 has a configuration in which multiple inner rotor core plates 261 are stacked with gaps in the axial direction. Similarly, outer rotor core 242 has a configuration in which multiple outer rotor core plates 262 are stacked with gaps in the axial direction.

[0081] At least one of the rotor core plates 260, the inner rotor core plate 261 and the outer rotor core plate 262, has a third convex portion 83 that protrudes in the axial direction and is provided along the pole surface 51 of the magnet 50 at the end on the side where the pole surface 51 of the magnet 50 is arranged.

[0082] 17 and 18 illustrate two third convex portions 83, that is, third convex portion 83a and third convex portion 83b, which correspond to first convex portion 81a and first convex portion 81b described in embodiment 1. Third convex portion 83a corresponds to first convex portion 81a described in embodiment 1, and is provided at radially inner end portion 262b of outer rotor core plate 262 along pole surface 51 of magnet 50. Third convex portion 83b corresponds to first convex portion 81b described in embodiment 1, and is provided at radially outer end portion 261a of inner rotor core plate 261 along pole surface 51 of magnet 50.

[0083] In addition, in Figures 17 and 18, the rotor 220 has two third convex portions 83 provided at different positions, the third convex portion 83a and the third convex portion 83b, but it may have only one of the third convex portions 83, either the third convex portion 83a or the third convex portion 83b.

[0084] The third convex portion 83a and the third convex portion 83b are desirably provided along the entire surface of the magnetic pole surface 51 of the magnet 50. The third convex portion 83a and the third convex portion 83b may also be provided along a portion of the magnetic pole surface 51 of the magnet 50.

[0085] It is preferable that the third convex portion 83 a and the third convex portion 83 b are provided so as to be in contact with the magnetic pole surface 51 of the magnet 50 .

[0086] The third convex portion 83 contacts the axial end face of the rotor core plate 260 axially adjacent to the rotor core plate 260 on which the third convex portion 83 is formed, providing a gap between the rotor core plates 260 adjacent in the axial direction.

[0087] 17 and 18, outer rotor core plate 262 may further include a fourth protrusion 84 that is provided along the circumferential direction and protrudes in the axial direction at radially outer end 262a of outer rotor core plate 262. Fourth protrusion 84 corresponds to second protrusion 82 described in embodiment 1. Fourth convex portion 84 may be provided around the entire circumference of radially outer end portion 262a of outer rotor core plate 262. Furthermore, fourth convex portion 84 may be provided only on a portion of radially outer end portion 262a of outer rotor core plate 262 that faces pole face 51 of magnet 50. Note that in Figures 17 and 18, rotor 220 has two third convex portions 83 and fourth convex portion 84 provided at different positions of third convex portion 83a and third convex portion 83b, but rotor 220 may have third convex portion 83 and fourth convex portion 84 at either third convex portion 83a or third convex portion 83b.

[0088] The fourth convex portion 84 contacts the axial end face of the rotor core plate 260 that is axially adjacent to the rotor core plate 260 on which the fourth convex portion 84 is formed, providing a gap between the axially adjacent rotor core plates 260.

[0089] Rotor core plate 260 including inner rotor core plate 261 and outer rotor core plate 262 is a thin plate made of a magnetic material with high magnetic permeability, and is made of, for example, an iron-based metal.

[0090] <Manufacturing Method of the Second Embodiment> Next, a method for manufacturing rotor 220 according to the second embodiment of the present disclosure will be described with reference to Fig. 19. Fig. 19 is a flowchart showing the method for manufacturing rotor 220.

[0091] As shown in FIG. 19, the manufacturing process of the rotor 220 includes steps 21 (S21) to 24 (S24) which will be described below.

[0092] In the formation process of step 21 (S21), a third convex portion 83 is formed on at least one of rotor core plates 260, i.e., inner rotor core plate 261 forming inner rotor core 241 and outer rotor core plate 262 forming outer rotor core 242, at the end on the side where pole face 51 of magnet 50 is arranged, along pole face 51 of magnet 50, and protruding in the axial direction.

[0093] In forming step S21, the procedure for forming third convex portion 83 is basically the same as in forming step S01 of rotor 20 in the first embodiment. Third convex portion 83 is formed by performing punching and bending on at least one of rotor core plates 260, inner rotor core plate 261 and outer rotor core plate 262. First, rotor core plate 260 is punched so as to form a protruding portion (not shown) at the end on the side where magnetic pole face 51 of magnet 50 is arranged. Next, third convex portion 83 is formed by bending the protruding portion formed on rotor core plate 260 at a right angle (90°) axially outward. Punching and bending may be performed simultaneously using a die.

[0094] Third convex portion 83 may be formed by adhering or welding a block that will become third convex portion 83 to rotor core plate 260. The block is made of a magnetic material, and is desirably made of the same material as rotor core plate 260. According to the method of adhering or welding a block, there is no need to form a protrusion during punching, and rotor core plate 260 that has been punched into a simple shape is adhered or welded to the block, making it easy to change the width of third convex portion 83, etc.

[0095] In a first lamination step of step 22a (S22a), multiple inner rotor core plates 261 that have undergone forming step S21 are stacked with gaps between axially adjacent inner rotor core plates 261 to form inner rotor core 241.

[0096] A procedure for stacking inner rotor core plates 261 in first lamination step S22a will be described. When inner rotor core plate 261 has third convex portion 83 formed thereon, third convex portion 83 formed on inner rotor core plate 261 contacts the axial end face of inner rotor core plate 261 axially adjacent to inner rotor core plate 261 with third convex portion 83 formed thereon. Therefore, third convex portion 83 formed on inner rotor core plate 261 allows the plates to be stacked with a gap between axially adjacent inner rotor core plates 261.

[0097] When inner rotor core plate 261 does not have third protrusion 83, a mating portion (not shown) that can be mated with shaft 30 can be provided between inner rotor core plate 261, allowing stacking with a gap between axially adjacent inner rotor core plates 261. This method can also be performed to bond shaft 30 and inner rotor core plate 261, which is part of the bonding process in step 23 (S23) described later. For example, by providing a mating convex portion (not shown) on shaft 30 and providing a mating concave portion (not shown) on inner rotor core plate 261, inner rotor core plate 261 can be positioned in the axial direction while being stacked with a gap between inner rotor core plates 261. Note that a mating concave portion may be provided on shaft 30, and a mating convex portion may be provided on inner rotor core plate 261.

[0098] Furthermore, the mating portion allows inner rotor core plate 261 to be positioned in the radial and circumferential directions and stacked. Note that positioning pins (not shown) may be used to position inner rotor core plate 261 in the radial and circumferential directions. The positioning pins are arranged, for example, in positions contacting the radial outside of inner rotor core plate 261. Inner rotor core plate 261 is stacked while being positioned in the radial and circumferential directions by arranging the positioning pins of the mold to contact the outer periphery of inner rotor core plate 261.

[0099] Note that, as long as the function of stacking inner rotor core plates 261 with a gap between axially adjacent inner rotor core plates 261 is satisfied, a joint portion need not be provided between shaft 30 and inner rotor core plates 261. For example, inner rotor core plates 261 may be stacked with a gap between them using a spacer (not shown). Also, inner rotor core plates 261 may be stacked with a gap between them by providing a thin layer (not shown) between inner rotor core plates 261 that can bond the inner rotor core plates 261 together.

[0100] In a second lamination process of step 22b (S22b), multiple outer rotor core plates 262 that have undergone forming process S21 are stacked with gaps between axially adjacent outer rotor core plates 262 to form outer rotor core 242.

[0101] A procedure for stacking outer rotor core plates 262 in second lamination step S22b will be described. When third convex portions 83 are formed on outer rotor core plates 262, third convex portions 83 formed on outer rotor core plates 262 contact the axial end face of outer rotor core plates 262 axially adjacent to outer rotor core plates 262 on which third convex portions 83 are formed. Therefore, third convex portions 83 formed on outer rotor core plates 262 allow the plates to be stacked with a gap between axially adjacent outer rotor core plates 262.

[0102] When third convex portions 83 are not formed on outer rotor core plates 262, outer rotor core plates 262 can be stacked with a gap provided between axially adjacent outer rotor core plates 262, for example, by using a spacer. By alternately stacking outer rotor core plates 262 and spacers, a gap is formed between outer rotor core plates 262 by the thickness of the spacer. Furthermore, outer rotor core plates 262 may be stacked with a gap provided between them by providing a thin layer between them that can bond outer rotor core plates 262 to each other.

[0103] In the joining process of step 23 (S23), main shaft 30 serving as the rotating shaft is placed inside inner rotor core 241, magnet 50 is placed radially outside inner rotor core 241, outer rotor core 242 is placed radially outside magnet 50, and main shaft 30, magnet 50, inner rotor core 241, and outer rotor core 242 are joined together. Methods for joining main shaft 30 and inner rotor core 241 include, for example, shrink fitting, cold fitting, press fitting, welding, and adhesive. Methods for fixing magnet 50 to inner rotor core 241 and outer rotor core 242 include, for example, adhesive.

[0104] As another joining method, main shaft 30, magnet 50, inner rotor core 241, and outer rotor core 242 can be joined by placing them in a molding die and injecting resin. This joining method using resin is preferable because it allows main shaft 30, magnet 50, inner rotor core 241, and outer rotor core 242 to be joined together in one step.

[0105] In the case of the resin-based coupling method, inner rotor core 241 is obtained by laminating inner rotor core plates 261 in which main shaft 30 is placed, and the diameter of the main shaft hole (not shown) is larger than the diameter of main shaft 30. By providing a gap between main shaft 30 and inner rotor core 241, main shaft 30 and inner rotor core 241 can be coupled with resin. In this case, when the resin-based coupling method is used, the radial thickness of inner rotor core 241 up to magnet 50 is minimized to a length that ensures a magnetic path that is not saturated by the magnetic flux generated by magnet 50. The resin-based coupling method can reduce the amount of material used for inner rotor core 241 by the difference between the diameter of main shaft 30 and the diameter of the main shaft hole, thereby reducing material costs. The resin-based coupling method can prevent electrolytic corrosion because main shaft 30 and inner rotor core 241 are not directly coupled but are coupled with resin.

[0106] In the magnetizing process of step 24 (S24), similarly to magnetizing process S04 in embodiment 1, a magnetizing device is used to impart magnetic force to magnet 50. In this way, rotor 220 in embodiment 2 can be obtained. Rotor 220 manufactured by such a manufacturing method can suppress reduction of the portion carrying the magnetic path in at least one of rotor cores 240, inner rotor core 241 and outer rotor core 242, and can effectively utilize the magnetic flux.

[0107] The rotating electric machine 210 can be manufactured by using the rotor 220 manufactured using the manufacturing method of the rotor 220 described in the flowchart of Figure 19, and by providing a stator arrangement process in which a stator 1 is arranged radially outside the rotor 220 via an air gap.

[0108] <Effects of the Second Embodiment> Next, the operation and effect of rotor 220 and rotating electric machine 210 according to embodiment 2 of the present disclosure will be described with reference to Fig. 20. Fig. 20 is a schematic diagram showing magnetic flux in rotor 220 according to embodiment 2 of the present disclosure, and is a schematic cross-sectional view corresponding to line segment AA shown in Fig. 2. In Fig. 20, the magnetic flux is indicated by a dashed line. Note that Fig. 20 shows the radial direction (R) and the circumferential direction (P).

[0109] First, attention is paid to the magnetic flux in outer rotor core 242 of rotor 220. As shown in FIG. 20, outer rotor core 242 of rotor 220 is disposed radially outside magnet 50, and is disposed as structure 90 at a predetermined interval in the circumferential direction with respect to main shaft 30. Of two structures 90 adjacent to each other with a gap in the circumferential direction, magnetic flux generated from pole face 51 of magnet 50 of one structure 90 passes through outer rotor core plate 262 of one structure 90, air gap 2 between outer rotor core 242 of one structure 90 and stator 1, stator 1, air gap 2 between outer rotor core 242 of the other structure 90 and stator 1, and outer rotor core 242 of the other structure 90, toward pole face 51 of magnet 50 of the other structure 90. That is, outer rotor core 242 serves as a magnetic path between stator 1 and magnet 50 with air gap 2 sandwiched between them on the radial outside. Next, attention is given to the magnetic flux in inner rotor core 241 of rotor 220. The magnetic flux in inner rotor core 241 of rotor 220 is generated from one pole face 51 of magnet 50, passes through inner rotor core plate 261, and heads toward the other pole face 51 of adjacent magnet 50. That is, inner rotor core 241 provides a magnetic path between magnets 50 adjacent in the circumferential direction.

[0110] As in the first embodiment, rotor 220 of the second embodiment of the present disclosure has third convex portion 83 formed at the end on the side where pole face 51 of magnet 50 is arranged, and protruding in the axial direction, along pole face 51 of magnet 50. Third convex portion 83 is provided at a position where magnetic flux passes, and third convex portion 83 becomes a magnetic path, thereby suppressing reduction of a portion of rotor core 240 that serves as the magnetic path between stator 1 and magnet 50 in at least one of inner rotor core 241 and outer rotor core 242. For example, third convex portion 83a is provided at radially inner end 262b of outer rotor core plate 262 along pole face 51 of magnet 50, and thus it is possible to suppress reduction of a portion of outer rotor core 242 that serves as the magnetic path between stator 1 and magnet 50. Since the third convex portion 83b is provided on the radially outer end portion 261a of the inner rotor core plate 261, along the pole face 51 of the magnet 50, it is possible to suppress reduction in the portion of the inner rotor core 241 that is responsible for the magnetic path between circumferentially adjacent magnets 50. In this way, in rotor 220 of embodiment 2 of the present disclosure, third convex portion 83 is provided along pole face 51 of magnet 50 at the end of at least one of rotor cores 240, inner rotor core 241 and outer rotor core 242, on the side where pole face 51 of magnet 50 is arranged. Therefore, when a gap is provided between rotor cores 240, reduction of the portion that carries the magnetic path in at least one of rotor cores 240, inner rotor core 241 and outer rotor core 242, can be suppressed, and the magnetic flux can be effectively utilized.

[0111] It is desirable that third convex portion 83 is provided at an end of rotor core plate 260 where both of two magnetic pole faces 51 of magnet 50 are arranged. That is, as shown in Fig. 20, third convex portion 83 is provided along magnetic pole face 51 of magnet 50 at the end of inner rotor core 241 and outer rotor core 242 on the side where magnetic pole face 51 of magnet 50 is arranged, thereby suppressing reduction of the portions carrying the magnetic path in both rotor cores 240 of inner rotor core 241 and outer rotor core 242, and enabling more effective use of the magnetic flux.

[0112] The end of the rotor core plate 260 on which the pole face 51 of the magnet 50 is arranged, where the third convex portion 83 is formed, is the position on the rotor core plate 260 closest to the pole face 51 of the magnet 50. The closer the position at which the third convex portion 83 is formed to the pole face 51 of the magnet 50, the smaller the gap between the third convex portion 83 and the pole face 51 of the magnet 50, and the less magnetic flux passes through the air or non-magnetic material, so the third convex portion 83 is formed at the end of the rotor core plate 260 on which the pole face 51 of the magnet 50 is arranged.

[0113] It is desirable that the third convex portion 83 be formed so as to be in contact with the magnetic pole surface 51 of the magnet 50. By forming the third convex portion 83 so as to be in contact with the magnetic pole surface 51 of the magnet 50, the gap between the third convex portion 83 and the magnetic pole surface 51 of the magnet 50 can be minimized, thereby further suppressing magnetic flux leakage and enabling effective use of the magnetic flux.

[0114] 20, by further providing fourth convex portion 84, magnetic flux leakage can be further suppressed and magnetic flux can be effectively utilized. Fourth convex portion 84 is provided along the circumferential direction at radially outer end 262a of outer rotor core plate 262, and therefore it is possible to suppress reduction of the portion of outer rotor core 242 that carries the magnetic path between stator 1 and magnet 50. As a result, leakage of the magnetic flux passing between stator 1 and magnet 50 in the air or non-magnetic material is suppressed, and the magnetic flux can be effectively utilized.

[0115] By making effective use of the magnetic flux, for example, it is possible to suppress a decrease in torque, as in the first embodiment. When magnetic flux leakage occurs in rotor 220, the strength of the magnetic field produced by magnets 50 weakens, and the torque generated by the interaction with the rotating magnetic field decreases. According to rotor 220 according to the second embodiment of the present disclosure, third convex portion 83 suppresses magnetic flux leakage and makes effective use of magnetic flux, so that it is possible to suppress the weakening of the magnetic field produced by magnets 50 and obtain sufficient torque. Furthermore, by making effective use of the magnetic flux, it is possible to suppress a decrease in the power efficiency of the rotating electric machine 210. When magnetic flux leakage occurs in the rotor 220, the torque decreases by an amount corresponding to the leaked magnetic flux, and therefore it is necessary to strengthen the applied current. According to the rotor 220 according to the second embodiment of the present disclosure, the third convex portion 83 suppresses magnetic flux leakage and makes effective use of the magnetic flux, thereby suppressing a decrease in torque and a decrease in power efficiency.

[0116] Furthermore, according to rotor 220 according to embodiment 2 of the present disclosure, third convex portion 83a and third convex portion 83b effectively utilize the magnetic flux near magnet 50, thereby improving the magnetization effect in magnetization step S24, which is one of the manufacturing steps. Third convex portion 83a and third convex portion 83b, which have high magnetic permeability, reduce magnetic resistance near magnet 50, making it easier for magnetic flux to pass through magnet 50 during magnetization, and improving the magnetization effect.

[0117] When the third convex portion 83 contacts the axial end face of the rotor core plate 260 adjacent in the axial direction to the rotor core plate 260 on which the third convex portion 83 is formed, the third convex portion 83 not only serves to suppress the reduction of the portion of the rotor core 240 that carries the magnetic path, but also serves to provide a gap between the axially adjacent rotor core plates 260. The third convex portion 83 has a simple structure, so that a gap can be provided between the axially adjacent rotor core plates 260, thereby suppressing manufacturing costs. In addition, the more third convex portions 83 are provided, the more stably a gap can be provided between the axially adjacent rotor core plates 60.

[0118] As with the third convex portion 83, when the fourth convex portion 84 contacts the axial end face of the rotor core plate 60 adjacent to the rotor core plate 60 on which the fourth convex portion 84 is formed, the fourth convex portion 84 not only serves to suppress the reduction of the portion of the rotor core 240 that carries the magnetic path, but also serves to provide a gap between the rotor core plates 60 adjacent in the axial direction. The simply structured fourth convex portion 84 allows a gap to be provided between the rotor core plates 260 adjacent in the axial direction, thereby reducing manufacturing costs. Furthermore, by forming the fourth convex portion 84 in addition to the third convex portion 83, a gap can be provided more stably between the rotor core plates 260 adjacent in the axial direction.

[0119] Furthermore, in rotor 220 according to the second embodiment of the present disclosure, rotor core plate 260 is separated into inner rotor core 241 and outer rotor core 242 on the radial inside and outside of magnet 50. Magnet 50 and outer rotor core 242 arranged radially outside inner rotor core 241 are arranged as structures 90 at a predetermined interval in the circumferential direction with respect to main shaft 30, the number of poles of rotor 220, and a gap is provided between the end faces in the circumferential direction of adjacent structures 90. The gap between the end faces in the circumferential direction of adjacent structures 90 is made of air or a non-magnetic material. In other words, since a bridge formed between magnets 50 adjacent in the circumferential direction is eliminated, the magnetic flux leaking between magnets 50 adjacent in the circumferential direction can be reduced and the magnetic flux can be effectively utilized.

[0120] As described above, according to rotor 220 and rotating electric machine 210 and the manufacturing method of rotor 220 and rotating electric machine 210 of embodiment 2 of the present disclosure, at least one of rotor core plates 260, inner rotor core plate 261 and outer rotor core plate 262, is provided with a third convex portion 83 that is provided along pole face 51 of magnet 50 and protrudes in the axial direction at the end on the side where pole face 51 of magnet 50 is arranged. By providing a gap between rotor core plates 260 of rotor 220 of IPM structure, it is possible to effectively utilize the magnetic flux by suppressing the reduction of the portion that carries the magnetic path in at least one of rotor cores 240, inner rotor core 241 and outer rotor core 242.

[0121] Furthermore, according to the rotor 220 and the rotating electric machine 210 and the manufacturing method of the rotor 220 and the rotating electric machine 210 of the second embodiment of the present disclosure, the third convex portion 83 having a simple structure can provide a gap between adjacent rotor core plates 260 in the axial direction, thereby reducing manufacturing costs.

[0122] Furthermore, according to the rotor 220 and rotating electric machine 210 and the manufacturing method of the rotor 220 and rotating electric machine 210 of embodiment 2 of the present disclosure, by separating the rotor core plates 260 radially inside and outside the magnets 50 and making the rotor core 240 a bridgeless structure, it is possible to reduce magnetic flux leakage between circumferentially adjacent magnets 50 and to make effective use of the magnetic flux.

[0123] Although the present disclosure has been described based on each embodiment, the present disclosure is not limited to each embodiment. In addition, appropriate combinations, modifications, and omissions of each embodiment are also within the scope of the technical idea of ​​the present disclosure.

[0124] Various aspects of the present disclosure are summarized below as appendices.

[0125] (Appendix 1) A main shaft that serves as the axis of rotation; A rotor core disposed radially outside the main shaft; a magnet disposed inside the rotor core and having a pole face; The rotor core is configured such that a plurality of rotor core plates are stacked with gaps in the axial direction, The rotor core plate is formed with magnet holes in which the magnets are arranged, and a first convex portion that is provided along the magnetic pole surface of the magnet at an end of the magnet hole on the side where the magnetic pole surface of the magnet is arranged and that protrudes in the axial direction. Rotor. (Appendix 2) The first convex portion is provided so as to be in contact with the magnetic pole surface of the magnet. 2. A rotor as described in claim 1. (Appendix 3) the first convex portion is in contact with an axial end surface of the rotor core plate adjacent to the rotor core plate on which the first convex portion is formed, and a gap is provided between the rotor core plates adjacent in the axial direction. 3. A rotor according to claim 1 or 2. (Appendix 4) a second protrusion provided along a circumferential direction at a position on an outer periphery of the rotor core plate facing the magnetic pole face of the magnet and protruding in an axial direction; 4. A rotor according to any one of claims 1 to 3. (Appendix 5) the second protrusion is in contact with an axial end surface of the rotor core plate adjacent to the rotor core plate on which the second protrusion is formed, and a gap is provided between the rotor core plates adjacent in the axial direction. 5. A rotor as described in claim 4. (Appendix 6) A main shaft that serves as the axis of rotation; an inner rotor core arranged radially outward of the main shaft; a magnet disposed radially outward of the inner rotor core and having a pole face; an outer rotor core arranged radially outside the magnet; a plurality of structures formed from the magnets arranged radially outside the inner rotor core and the outer rotor core are arranged in a circumferential direction about the shaft, and a gap is provided between circumferential end faces of adjacent structures, the inner rotor core has a configuration in which a plurality of inner rotor core plates are stacked with gaps in the axial direction, the outer rotor core has a configuration in which a plurality of outer rotor core plates are stacked with gaps in the axial direction, At least one of the inner rotor core plate and the outer rotor core plate has a third convex portion formed at an end portion on a side where the magnetic pole surface of the magnet is arranged, the third convex portion being provided along the magnetic pole surface of the magnet and protruding in an axial direction. Rotor. (Appendix 7) The third convex portion is provided so as to be in contact with the magnetic pole surface of the magnet. 7. A rotor as described in claim 6. (Appendix 8) the third protrusion is in contact with an axial end surface of the rotor core plate adjacent to the rotor core plate on which the third protrusion is formed, and a gap is provided between the rotor core plates adjacent in the axial direction. 8. A rotor according to claim 6 or 7. (Appendix 9) a fourth protrusion provided along a circumferential direction at a radially outer end of the outer rotor core plate and protruding in an axial direction; 9. A rotor according to any one of claims 5 to 8. (Appendix 10) the fourth protrusion is in contact with an axial end surface of the rotor core plate adjacent to the rotor core plate on which the fourth protrusion is formed, and a gap is provided between the rotor core plates adjacent in the axial direction. 10. The rotor of claim 9. (Appendix 11) A rotor according to any one of claims 1 to 10; A stator disposed radially opposite to the rotor; A rotating electric machine comprising: (Appendix 12) a forming process for forming a magnet hole in a rotor core plate, in which a magnet having a pole surface is disposed, and a first convex portion that is provided along the pole surface of the magnet and protrudes in an axial direction at an end of the magnet hole on the side where the pole surface of the magnet is disposed; a lamination step of laminating the rotor core plates with gaps between adjacent rotor core plates in the axial direction to form a rotor core; a coupling step of disposing a main shaft serving as a rotating shaft and the magnet inside the rotor core, and coupling the main shaft, the magnet, and the rotor core; a magnetizing step of applying a magnetic force to the magnet; A method for manufacturing a rotor comprising the steps of: (Appendix 13) 1. A method for manufacturing a rotor comprising: a main shaft serving as a rotating shaft; an inner rotor core arranged radially outward of the main shaft; a magnet arranged radially outward of the inner rotor core, the magnet having a pole face; and an outer rotor core arranged radially outward of the magnet, the method comprising the steps of: forming a third convex portion that is provided along the magnetic pole faces of the magnets and protrudes in an axial direction on an end portion of at least one of an inner rotor core plate forming the inner rotor core and an outer rotor core plate forming the outer rotor core, the third convex portion being provided along the magnetic pole faces of the magnets and protruding in an axial direction; a first lamination step of stacking the inner rotor core plates with a gap between adjacent inner rotor core plates in the axial direction to form the inner rotor core; a second lamination step of stacking the outer rotor core plates with gaps between adjacent outer rotor core plates in the axial direction to form the outer rotor core; a coupling step of disposing a main shaft serving as a rotating shaft inside the inner rotor core, disposing the magnets radially outside the inner rotor core, disposing the outer rotor core radially outside the magnets, and coupling the main shaft, the magnets, the inner rotor core, and the outer rotor core; a magnetizing step of applying a magnetic force to the magnet; A method for manufacturing a rotor comprising the steps of: (Appendix 14) Using a rotor manufactured by the rotor manufacturing method described in Supplementary Note 12 or Supplementary Note 13, A stator arrangement step of arranging a stator so as to face the rotor in a radial direction, A method for manufacturing a rotating electric machine. [Explanation of symbols]

[0126] 10, 210 Rotating Electric Machine 1 Stator 2. Air gap 3 Teeth 4 Stator Winding 20, 21, 22, 23, 24, 220 Rotor 30 main shaft 40, 240 Rotor core 241 Inner rotor core 242 Outer rotor core 241a Radially outer end of inner rotor core 242a Radially outer end of outer rotor core 242b Radially inner end of outer rotor core 50 Magnet 61 Magnetic pole face 60, 260 Rotor core plate 261 Inner rotor core plate 262 Outer rotor core plate 261a Radially outer end of inner rotor core plate 262a Radially outer end of outer rotor core plate 262b Radially inner end of outer rotor core plate 60a Outer periphery of rotor core plate 60b Overhang 70 Magnet hole 70a: radially outer end of magnet hole 70b radially inner end of magnet hole 81, 81a, 81b First convex portion 82 Second convex part 83, 83a, 83b Third convex part 84 Fourth convex part 90 Structure S01 Forming process S02 Lamination process S03 Bonding process S04 Magnetization process S21 Forming process S22a First lamination process S22b Second lamination process S23 Bonding process S24 Magnetization Engineering

Claims

1. A main shaft that serves as the axis of rotation; A rotor core disposed radially outside the main shaft; a magnet disposed inside the rotor core and having a pole face; The rotor core is configured such that a plurality of rotor core plates are stacked with gaps in the axial direction, The rotor core plate is formed with magnet holes in which the magnets are arranged, and a first convex portion that is provided along the magnetic pole surface of the magnet at an end of the magnet hole on the side where the magnetic pole surface of the magnet is arranged and that protrudes in the axial direction. Rotor.

2. The first convex portion is provided so as to be in contact with the magnetic pole surface of the magnet. The rotor according to claim 1 .

3. the first convex portion is in contact with an axial end surface of the rotor core plate adjacent to the rotor core plate on which the first convex portion is formed, and a gap is provided between the rotor core plates adjacent in the axial direction. The rotor according to claim 1 .

4. a second protrusion provided along a circumferential direction at a position on an outer periphery of the rotor core plate facing the pole face of the magnet and protruding in an axial direction; The rotor according to claim 1 .

5. the second protrusion is in contact with an axial end surface of the rotor core plate adjacent to the rotor core plate on which the second protrusion is formed, and a gap is provided between the rotor core plates adjacent in the axial direction. The rotor according to claim 4.

6. A main shaft that serves as the axis of rotation; an inner rotor core arranged radially outward of the main shaft; a magnet disposed radially outward of the inner rotor core and having a pole face; an outer rotor core arranged radially outside the magnet; a plurality of structures formed from the magnets arranged radially outside the inner rotor core and the outer rotor core are arranged in a circumferential direction about the shaft, and a gap is provided between circumferential end faces of adjacent structures, the inner rotor core has a configuration in which a plurality of inner rotor core plates are stacked with gaps in the axial direction, The outer rotor core has a configuration in which a plurality of outer rotor core plates are stacked with gaps in the axial direction, At least one of the inner rotor core plate and the outer rotor core plate has a third convex portion formed at an end portion on a side where the magnetic pole surface of the magnet is arranged, the third convex portion being provided along the magnetic pole surface of the magnet and protruding in an axial direction. Rotor.

7. The third convex portion is provided so as to be in contact with the magnetic pole surface of the magnet. The rotor according to claim 6.

8. the third protrusion is in contact with an axial end surface of the rotor core plate adjacent to the rotor core plate on which the third protrusion is formed, and a gap is provided between the rotor core plates adjacent in the axial direction. The rotor according to claim 6.

9. a fourth protrusion provided along a circumferential direction at a radially outer end of the outer rotor core plate and protruding in an axial direction; The rotor according to claim 6.

10. the fourth protrusion is in contact with an axial end surface of the rotor core plate adjacent to the rotor core plate on which the fourth protrusion is formed, and a gap is provided between the rotor core plates adjacent in the axial direction. The rotor according to claim 9.

11. A rotor according to any one of claims 1 to 10; A stator disposed radially opposite to the rotor; A rotating electric machine comprising:

12. a forming process for forming a magnet hole in a rotor core plate, in which a magnet having a magnetic pole surface is disposed, and a first convex portion that is provided along the magnetic pole surface of the magnet at an end of the magnet hole on the side where the magnetic pole surface of the magnet is disposed and that protrudes in an axial direction; a lamination step of laminating the rotor core plates with gaps between adjacent rotor core plates in the axial direction to form a rotor core; a coupling step of disposing a main shaft serving as a rotating shaft and the magnet inside the rotor core, and coupling the main shaft, the magnet, and the rotor core; a magnetizing step of applying a magnetic force to the magnet; A method for manufacturing a rotor comprising the steps of:

13. 1. A method for manufacturing a rotor comprising: a main shaft serving as a rotating shaft; an inner rotor core arranged radially outward of the main shaft; a magnet arranged radially outward of the inner rotor core, the magnet having a pole face; and an outer rotor core arranged radially outward of the magnet, the method comprising the steps of: forming a third convex portion that is provided along the magnetic pole faces of the magnets and protrudes in an axial direction on an end portion of at least one of an inner rotor core plate forming the inner rotor core and an outer rotor core plate forming the outer rotor core, the third convex portion being provided along the magnetic pole faces of the magnets and protruding in an axial direction; a first lamination step of stacking the inner rotor core plates with a gap between adjacent inner rotor core plates in the axial direction to form the inner rotor core; a second lamination step of stacking the outer rotor core plates with gaps between adjacent outer rotor core plates in the axial direction to form the outer rotor core; a coupling step of disposing a main shaft serving as a rotating shaft inside the inner rotor core, disposing the magnets radially outside the inner rotor core, disposing the outer rotor core radially outside the magnets, and coupling the main shaft, the magnets, the inner rotor core, and the outer rotor core; a magnetizing step of applying a magnetic force to the magnet; A method for manufacturing a rotor comprising the steps of:

14. Using a rotor manufactured by the rotor manufacturing method according to claim 12 or 13, A stator arrangement step of arranging a stator radially opposite to the rotor, A method for manufacturing a rotating electric machine.

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