Rotor and rotor creation method

Abstract

To provide a rotor and a rotor creation method that can reduce manufacturing cost.SOLUTION: A rotor 13 has a rotor core 130, holes 131, and rod-like members. The rotor core has laminated annular steel plates. The holes are provided in the rotor core and extend in a direction in which the annular steel plates are laminated. The rod-like members are located in the holes. The rod-like members each have laminated members.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to rotors and methods of producing rotors. [Background technology]

[0002] The rotor core of Patent Document 1 has an annular core plate formed by connecting arc-shaped core plate pieces, and rod-shaped members inserted into all of a plurality of through holes aligned in the stacking direction in each core plate piece. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-143872 Summary of the Invention [Problem to be solved by the invention]

[0004] If the rod-shaped members to be inserted into all of the plurality of through holes are formed separately from the rotor core, the number of steps increases and raw materials and costs tend to increase.

[0005] The present disclosure has been made in view of the above-mentioned problems, and its purpose is to provide a rotor and a rotor manufacturing method that can reduce manufacturing costs. [Means for solving the problem]

[0006] An exemplary rotor according to the present disclosure includes a rotor core, a hole, and a rod-shaped member. The rotor core is made up of stacked annular steel plates. The hole is provided in the rotor core and extends in the direction in which the annular steel plates are stacked. The rod-shaped member is located in the hole. The rod-shaped member is made up of stacked members.

[0007] Another exemplary rotor of the present disclosure includes a rotor core, a hole, and a rod-shaped member. The rotor core is formed by laminating annular steel plates. The hole is provided in the rotor core and extends in the direction in which the annular steel plates are laminated. The rod-shaped member is located in the hole. The hole has a first hole and a second hole. The first hole has a first diameter. The second hole has a second diameter smaller than the first diameter. The rod-shaped member is located in the second hole.

[0008] An exemplary rotor production method of the present disclosure includes the steps of punching out an annular steel plate, punching out the annular steel plate to create an opening, stacking the annular steel plate to create a rotor core, stacking separated members punched out from the annular steel plate when creating the opening to create a rod-shaped member, and arranging the rod-shaped member in a hole connected to the opening in the stacking direction of the annular steel plate. [Effects of the Invention]

[0009] The present exemplary disclosure allows for reduced manufacturing costs. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a diagram showing the appearance of a motor including a rotor according to an exemplary embodiment. [Figure 2] FIG. 2 illustrates an exemplary embodiment rotor. [Figure 3] FIG. 3 is a view of the rotor as seen from one side in the first direction. [Figure 4] FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. [Figure 5] FIG. 5 is a diagram schematically showing a cross-sectional view of FIG. [Figure 6] FIG. 6 is a diagram showing a schematic diagram of the press working process in which lamination is formed. [Figure 7] FIG. 7 is a diagram showing a schematic diagram of bending, which is one of the press working processes. [Figure 8]FIG. 8 is a diagram showing a schematic diagram of a cutting process among the press processes. [Figure 9] FIG. 9 is a diagram showing a schematic view of lamination of cut parts. [Figure 10] FIG. 10 is a flowchart illustrating an exemplary embodiment rotor generation method. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings. In the drawings, identical or corresponding parts are designated by the same reference numerals, and description thereof will not be repeated. For ease of understanding, the central axis direction substantially parallel to the motor's rotation shaft will be referred to as the first direction D1, one side of the first direction D1 will be referred to as the first direction one side D11, and the other side of the first direction D1 will be referred to as the first direction other side D12. Furthermore, the radial direction centered on the motor's rotation shaft will be referred to as the radial direction D2, and the circumferential direction centered on the motor's rotation shaft will be referred to as the circumferential direction D3. However, these definitions of directions are merely for convenience of explanation, and do not limit the orientation of the motor according to the present invention during use, except when it is necessary to specifically define the horizontal and vertical directions. Furthermore, in this application, the term "orthogonal directions" also includes substantially orthogonal directions.

[0012] A motor 1 according to an exemplary embodiment will be described with reference to Fig. 1. Fig. 1 is a diagram showing the external appearance of a motor 1 including a rotor 13 according to an exemplary embodiment.

[0013] As shown in FIG. 1, the motor 1 includes a motor case 11, a stator 12, a rotor 13, and a shaft .

[0014] In this embodiment, the motor 1 is a three-phase AC motor. A three-phase AC motor is a typical example of the motor 1, and the form and type of the motor 1 are not particularly limited.

[0015] Stator 12 has an annular shape centered on central axis J extending in first direction D1. Stator 12 has an annular or cylindrical stator core (not shown), a plurality of teeth provided on the inner peripheral surface of the stator core, and a plurality of coils (not shown) wound around the plurality of teeth, respectively.

[0016] Next, the structure of rotor 13 according to an exemplary embodiment will be described with reference to Figures 1 to 5. Figure 2 is a diagram illustrating rotor 13 according to an exemplary embodiment. Figure 3 is a diagram illustrating rotor 13 as viewed from one side D11 in the first direction. Figure 4 is a cross-sectional view taken along line IV-IV in Figure 3. Figure 5 is a diagram schematically illustrating the cross-sectional view of Figure 4.

[0017] The rotor 13 faces the stator 12 in the radial direction D2. In this embodiment, the rotor 13 is located inside the stator 12 in the radial direction D2. As shown in FIG. 2, the rotor 13 has a rotor core 130 and a magnet 15 arranged on the rotor core 130. Due to the interaction between the magnet 15 and a plurality of coils (not shown) of the stator 12, the rotor 13 rotates in the circumferential direction D3 around the central axis J relative to the stator 12. In other words, in this embodiment, the motor 1 is an inner rotor type motor. However, the motor 1 may also be an outer rotor type motor in which the rotor 13 is located outside the stator 12 in the radial direction D2.

[0018] A shaft 14 extending in a first direction D1 is attached to the rotor 13 (FIG. 1). The shaft 14 coincides with the central axis J. In other words, the shaft 14 is the rotation axis of the rotor 13 and extends in the axial direction along the central axis J. The stator 12 is located radially outward of the shaft 14.

[0019] As shown in FIGS. 2 to 5, the rotor core 130 is formed by stacking a plurality of laminations 21 in a first direction D1. That is, the stacking direction of the plurality of laminations 21 is the first direction D1. The laminations 21 are formed from electromagnetic steel sheets. The laminations 21 have an annular shape with a circular opening formed on the inside. The laminations 21 are an example of annular steel sheets. In this embodiment, the rotor core 130 is formed by stacking three types of laminations 21 having different shapes in the first direction D1. Specifically, from one side D11 in the first direction toward the other side D12 in the first direction, the plurality of laminations 21a, the plurality of laminations 21b, the plurality of laminations 21c, and the plurality of laminations 21a are stacked in this order.

[0020] Lamination 21a and lamination 21c have the same outer diameter, but the inner diameter of lamination 21c is smaller than the inner diameter of lamination 21a, i.e., the width of lamination 21c along radial direction D2 is greater than the width of lamination 21a along radial direction D2.

[0021] Lamination 21b has a smaller outer diameter than lamination 21a and the same inner diameter as lamination 21c.

[0022] Shaft 14 is attached to the inner circumferential surface of stacked laminations 21b and 21c. Magnet 15 is attached to the outer circumferential surface of stacked laminations 21b and 21c. Specifically, a portion of magnet 15 is held by lamination 21a, stacked laminations 21b, and lamination 21c, and magnet 15 covers the outer circumferential surfaces of stacked laminations 21b and 21c.

[0023] As shown in FIGS. 3 and 4 , the rotor core 130 has a plurality of holes 131 and a plurality of holes 132 extending in a first direction D1, which is the stacking direction of the plurality of laminations 21. As an example, the holes 131 and the holes 132 are circular through-holes that penetrate the rotor core 130 in the first direction D1. In this embodiment, five of the holes 131 and five of the holes 132 are provided, but the numbers of the holes 131 and the holes 132 are not particularly limited. For example, one of the holes 131 and one of the holes 132 may be provided. Furthermore, the number of the holes 131 and the number of the holes 132 may be different from each other. Furthermore, only one of the holes 131 and the holes 132 may be provided.

[0024] The rotor core 130 further has a fixing pin 31. The fixing pin 31 is positioned in at least one of the plurality of holes 131 and the plurality of holes 132. The fixing pin 31 is an example of a rod-shaped member. As shown in FIG. 5, the fixing pin 31 is formed by stacking a plurality of members, similar to the rotor core 130. The formation of the fixing pin 31 will be described later.

[0025] This allows the stacked laminations 21 to be connected to one another by the fixing pins 31. As a result, the laminations 21 are less likely to separate from one another. Furthermore, by forming the fixing pins 31 by laminating multiple members, which is the same process as forming the rotor core 130, it becomes possible to share manufacturing equipment. Therefore, the manufacturing costs for the rotor core 130 and the fixing pins 31 can be reduced.

[0026] For example, the members to be laminated at the fixing pins 31 are made of the same material as the laminations 21. For example, the remaining portion of the workpiece S, which will be described later, after the laminations 21 have been punched out can be used as the members to be laminated at the fixing pins 31. Therefore, the rotor core 130 and the fixing pins 31 can be manufactured using a small amount of raw material.

[0027] Specifically, the rotor core 130 is provided with at least two holes 131, or at least two holes 132. Alternatively, the rotor core 130 is provided with one hole 131 and one hole 132.

[0028] Hole 131 and hole 132 have different hole diameters. For example, as shown in FIG. 5, hole 131 has diameter d1. Hole 132 has diameter d2. Specifically, diameter d1 has a plus tolerance of 3 mm. Diameter d2 has a minus tolerance of 3 mm. In other words, diameter d2 is smaller than diameter d1. By providing holes 131 and 132 with different hole diameters, the rigidity of rotor core 130 can be increased compared to when only hole 131 with a large diameter is provided. Diameter d1 is an example of a first diameter. Diameter d2 is an example of a second diameter. Hole 131 is an example of a first hole. Hole 132 is an example of a second hole.

[0029] 3, the five holes 131 and the five holes 132 are arranged side by side in the circumferential direction D3 of the rotor core 130. Therefore, the number of locations where the fixing pins 31 can be arranged increases, and the number of connections between the laminations 21 increases, making it more difficult for the laminations 21 to separate from each other.

[0030] Specifically, in rotor core 130, holes 131 and holes 132 are arranged alternately along circumferential direction D3. For example, hole 132 is arranged point-symmetrically with respect to hole 131, with respect to the center of rotor core 130. This improves the weight balance of rotor core 130 along circumferential direction D3, making it easier to stabilize the rotation of rotor 13.

[0031] In this embodiment, the fixing pins 31 are positioned in at least some of the multiple holes 132. Fig. 3 shows an example in which the fixing pins 31 are positioned in only all five holes 132. By positioning the fixing pins 31 in the holes 132 with smaller diameters among the multiple holes 131 and 132, the raw materials for the fixing pins 31 can be reduced, and the cost of raw materials can be reduced.

[0032] 4 and 5, holes 131 and 132 are formed by connecting openings 221 and 222 provided in laminations 21 in first direction D1, respectively. In other words, stacked laminations 21 each have openings 221 and 222. The diameter of opening 221 is the same as diameter d1 of hole 131. The diameter of opening 222 is the same as diameter d2 of hole 132.

[0033] Next, the formation of the lamination 21 and the fixing pin 31 will be described with reference to Fig. 6 to Fig. 9. Fig. 6 is a diagram schematically showing the press working process in which the lamination 21 is formed. Fig. 7 is a diagram schematically showing the bending process in the press working. Fig. 8 is a diagram schematically showing the cutting process in the press working. Fig. 9 is a diagram schematically showing the stacking of parts that have been cut.

[0034] 6, the lamination 21 is formed by cutting (slicing) a workpiece S, which is a sheet steel plate, into the shape of the lamination 21. Specifically, a plurality of laminations 21a, a plurality of laminations 21c, a plurality of laminations 21b, and a plurality of laminations 21a are cut and punched out from the workpiece S, which is conveyed in a predetermined direction, in this order.

[0035] 7 to 9 show representatively the formation of opening 221 in lamination 21a. Figures 7 to 9 show cross sections taken along line VII-VII in Figure 6. In Figures 7 to 9, lamination 21a and opening 221 (separation member 301) are distinguished from each other by hatching to make the drawings easier to understand.

[0036] Hereinafter, the process for forming the lamination 21 will be referred to as press processing. Press processing includes a cutting process for cutting the workpiece S to punch out a steel plate of a specific shape, and a bending process for forming concaves and convexes on the workpiece S. When forming the opening 221, a circular separating member 301 is punched out from the workpiece S.

[0037] First, as shown in Fig. 7, when forming the opening 221, the workpiece S is bent. In the bending process when forming the opening 221, a predetermined force F1 is applied to the workpiece S being transported from above at a predetermined position by a punch 401. The range in which the predetermined force F1 is applied is a range having a diameter d0 that is smaller than the diameter d1 of the opening 221.

[0038] As a result, the workpiece S is formed with a recess 301b recessed downward from the surface of the upper side of the workpiece S, and a protrusion 301a protruding downward from the surface of the lower side opposite the recess 301b. The shape of the punch 401 is not particularly limited, and V-shaped, round V-shaped, and round (flat) shaped protrusions 301a and recesses 301b are formed depending on the shape of the punch 401. In FIGS. 7 to 9, the round (flat) shaped protrusions 301a and recesses 301b are described as an example.

[0039] Next, as shown in Fig. 8, cutting is performed on the workpiece S. In the cutting process for forming the opening 221, a predetermined force F2 is applied from above the workpiece S by a punch 402 to an area that includes the convex portion 301a and the concave portion 301b and is wider than the convex portion 301a and the concave portion 301b. The punch 402 has a circular shape with a diameter d1 that is the same as the opening 221.

[0040] As a result, the workpiece S is cut into the shape of the opening 221, and the separation member 301 is punched out of the workpiece S. A die 501 that supports the workpiece S is disposed below the workpiece S. The die 501 is provided with a hole that has the same shape as the opening 221 but a diameter d3 that is different from that of the opening 221. Typically, the hole provided in the die 501 is located directly below the punch 402. At this time, the diameter of the cut opening 221 is shaped to the diameter d1 of the punch 402.

[0041] On the other hand, the diameter of the separation member 301 punched out from the work S is adjusted to the diameter d3 of the hole provided in the die 501.

[0042] In this embodiment, a squeeze ring 502 is further disposed below the die 501. The squeeze ring 502 has a hole 503 that connects to a hole provided in the die 501, and a cylindrical side wall 504 that surrounds the periphery of the hole 503. The side wall 504 is capable of applying a predetermined force F3 toward the center of the hole 503 in a direction that intersects the vertical direction. The diameter of the hole 503 is the same as the diameter d3 of the hole provided in the die 501.

[0043] When the separating member 301 punched out from the workpiece S passes through the hole provided in the die 501 , it is supported by a force F 3 received from the side wall 504 of the squeeze ring 502 and remains in the hole 503 of the squeeze ring 502 .

[0044] Furthermore, when the next separating member 301 is punched out of the workpiece S, the next separating member 301 is pressed from above by the force F2 from the punch 402 and the force F3 from the side wall 504 onto the previous separating member 301 that remains in the hole 503 of the squeeze ring 502. As a result, the convex portion 301a of the next separating member 301 fits into the concave portion 301b of the previous separating member 301, and the separating members 301 come into close contact with each other.

[0045] By repeating the above processing, multiple separating members 301 are stacked and tightly adhered to each other, as shown in Fig. 9, to form a fixing pin 31. Typically, the number of stacked separating members 301 is the same as the number of stacked laminations 21. In the fixing pin 31, the recessed portion 301b of one separating member 301 is located at the protruding portion 301a of another separating member 301.

[0046] Laminations 21a, 21b, and 21c are punched out and stacked by a similar press process. As shown in FIG. 5, recesses and protrusions are formed in laminations 21a, 21b, and 21c, respectively, by bending. Therefore, stacked laminations 21a, 21b, and 21c are brought into close contact with each other to form rotor core 130. Note that opening 222 is formed in the same manner as opening 221. In this embodiment, separation member 302 punched out from workpiece S when forming opening 222 may or may not be stacked.

[0047] Fixing pins 31 with stacked separating members 301 are placed in holes 132 of the formed rotor core 130. In this way, by reusing the separating members 301 used when the openings 221 are formed, it is possible to inexpensively produce the rotor 13. Specifically, by setting the difference between the diameters d1 and d2 to within a plus or minus tolerance, it becomes possible to press-fit fixing pins 31 with diameter d3 of the separating members 301 used when the openings 221 are formed into holes 132 with diameter d2.

[0048] An exemplary embodiment rotor production method will now be described with reference to Figure 10. Figure 10 is a flow chart illustrating an exemplary embodiment rotor production method.

[0049] First, the workpiece S is bent to form the recessed portion 301b and the protruding portion 301a in the workpiece S (step S11).

[0050] Next, the workpiece S is cut to form the separation members 301 and 302 (step S12), and the openings 221 and 222 are formed (step S13).

[0051] The separating members 301 are stacked to form the fixing pins 31 (step S14).

[0052] The workpiece S having the openings 221 and 222 formed therein is subjected to a cutting process to cut out a plurality of laminations 21 (step S15).

[0053] The plurality of laminations 21 are stacked, the openings 221 of the plurality of laminations 21 are connected to form holes 131, and the openings 222 of the plurality of laminations 21 are connected to form holes 132 (step S16).

[0054] The fixing pin 31 is placed in the hole 132 (step S17).

[0055] In this embodiment, the fixing pin 31 may be formed by laminating a member other than the separating member 301. Furthermore, the fixing pin 31 may be formed by a method other than laminating members.

[0056] In this embodiment, the fixing pin 31 may be located only in the hole 132 out of the holes 131 and 132 .

[0057] The embodiments of the present disclosure have been described above with reference to the drawings. However, the present disclosure is not limited to the above embodiments and can be implemented in various forms without departing from the spirit and scope of the present disclosure. Furthermore, the components disclosed in the above embodiments can be modified as appropriate. For example, some of the components shown in one embodiment may be added to the components of another embodiment, or some of the components shown in one embodiment may be deleted from the embodiment.

[0058] Furthermore, the drawings mainly show each component in a schematic manner to facilitate understanding of the disclosure, and the thickness, length, number, spacing, etc. of each component shown in the drawings may differ from the actual ones due to the convenience of creating the drawings. Furthermore, the configurations of each component shown in the above embodiment are merely examples and are not particularly limited, and it goes without saying that various modifications are possible within a scope that does not substantially deviate from the effects of the present disclosure.

[0059] The present technology can be configured as follows. (1) a rotor core formed by laminating annular steel plates; a hole provided in the rotor core and extending in a direction in which the annular steel plates are stacked; a rod-shaped member positioned in the hole; and The rod-shaped member is a rotor in which members are stacked. (2) The rotor of (1), wherein the rod-shaped members to be stacked are made of the same material as the annular steel plate. (3) Two or more holes are provided in the rotor core, The rotor of (1) or (2), wherein the holes are arranged in a row in the circumferential direction of the rotor core. (4) The hole is a first hole having a first diameter; a second hole having a second diameter smaller than the first diameter; A rotor according to any one of (1) to (3), having: (5) The rotor (4) has the rod-shaped member positioned in the second hole. (6) The rotor of (4), wherein the second holes are arranged symmetrically with respect to the first holes, with the center of the rotor core being the symmetric point. (7) Each of the stacked annular steel plates has a first opening having the first diameter and a second opening having the second diameter, The first hole is formed such that the first opening is continuous in the stacking direction of the annular steel plate, The second hole is formed such that the second opening is connected in the stacking direction of the annular steel plate, The rotor according to any one of (4) to (6), wherein the rod-shaped member is a stack of separate members punched out from the annular steel plate when the first opening is formed. (8) a rotor core formed by laminating annular steel plates; a hole provided in the rotor core and extending in a direction in which the annular steel plates are stacked; a rod-shaped member positioned in the hole; and The hole is a first hole having a first diameter; a second hole having a second diameter smaller than the first diameter; and The rod-shaped member is positioned in the second hole. (9) stamping an annular steel plate; punching the annular steel plate to create an opening; laminating the annular steel plates to form a rotor core; a step of stacking separate members punched out from the annular steel plate to generate a rod-shaped member when generating the opening; placing the rod-shaped member in a hole in which the openings are connected in the stacking direction of the annular steel plate; A rotor generating method comprising: [Industrial Applicability]

[0060] The present disclosure is applicable to the field of motors. [Explanation of symbols]

[0061] 13: Rotor 21: Lamination 21a: Lamination 21b: Lamination 21c: Lamination 31: Fixed pin 130: Rotor core 131: Hole (1st hole) 132: Hole (2nd hole) 221: Opening (first opening) 222: Opening (second opening) 301: Separation member D1: First direction (stacking direction) d1: Diameter (first diameter) d2: Diameter (second diameter)

Claims

1. a rotor core formed by laminating annular steel plates; a hole provided in the rotor core and extending in a direction in which the annular steel plates are stacked; a rod-shaped member positioned in the hole; and The rod-shaped member is a rotor in which members are stacked.

2. 2. The rotor according to claim 1, wherein the laminated members of the rod-shaped member are made of the same material as the annular steel plate.

3. Two or more holes are provided in the rotor core, The rotor according to claim 1 or 2, wherein the holes are arranged side by side in the circumferential direction of the rotor core.

4. The hole is a first hole having a first diameter; a second hole having a second diameter smaller than the first diameter; 3. The rotor according to claim 1 or claim 2, wherein:

5. The rotor of claim 4 , wherein the rod-shaped member is located in the second hole.

6. The rotor according to claim 4 , wherein the second holes are arranged point-symmetrically with respect to the first holes, with the center of the rotor core being the point of symmetry.

7. Each of the stacked annular steel plates has a first opening having the first diameter and a second opening having the second diameter, The first hole is formed such that the first opening is continuous in the stacking direction of the annular steel plate, The second hole is formed such that the second opening is continuous in the stacking direction of the annular steel plate, The rotor according to claim 4 , wherein the rod-shaped member is made of a laminate of separate members punched out from the annular steel plate when the first opening is formed.

8. a rotor core formed by laminating annular steel plates; a hole provided in the rotor core and extending in a direction in which the annular steel plates are stacked; a rod-shaped member positioned in the hole; and The hole is a first hole having a first diameter; a second hole having a second diameter smaller than the first diameter; and The rod-shaped member is located in the second hole.

9. stamping an annular steel plate; punching the annular steel plate to create an opening; laminating the annular steel plates to form a rotor core; a step of stacking separate members punched out from the annular steel plate to generate a rod-shaped member when generating the opening; placing the rod-shaped member in a hole in which the openings are connected in the stacking direction of the annular steel plate; A rotor generating method comprising:

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