Rotor manufacturing apparatus and rotor manufacturing method

Abstract

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

Description

Technical Field

[0001] Embodiments of the present invention relate to a rotor manufacturing apparatus and a method for manufacturing a rotor.

Background Art

[0002] A surface magnet type: SPM (surface permanent magnetic) rotor in which magnets are attached to the outer periphery of a rotor core is known. In a large rotor, the magnetic force of the magnet also increases, and it is difficult to arrange the magnet on the outer peripheral surface of the rotor core while controlling the attractive force or repulsive force of the magnet.

Prior Art Documents

Patent Documents

[0003] q

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] [[ID=3 five]]The problem to be solved by the present invention is to provide a rotor manufacturing apparatus capable of smoothly arranging rotor magnets on the outer peripheral surface of a rotor core, and a method for manufacturing a rotor.

Means for Solving the Problems

[0005] The rotor manufacturing apparatus of this embodiment is a rotor manufacturing apparatus that attaches magnets to the outer circumferential surface of a rotor core that extends axially around a central axis. The rotor manufacturing apparatus has a rotor core support section and a magnet support mechanism. The rotor core support section supports the rotor core. The magnet support mechanism supports the magnets on the radially outer side of the rotor core. The magnet support mechanism has a pair of support members and a drive section. The pair of support members face each other in opposing directions perpendicular to both the radial and axial directions. The pair of support members have a magnet between them. The drive section moves the pair of support members closer to and further apart from each other in opposing directions. The pair of support members each have a support surface. The pair of support surfaces face each other in opposing directions. The pair of support surfaces contact the circumferential end faces of the magnets. The pair of support surfaces are inclined so that they move away from each other in opposing directions as they extend radially outward.

[0006] The rotor manufacturing method of this embodiment involves attaching magnets to the outer circumferential surface of a rotor core that extends axially around a central axis. The opposing directions are those perpendicular to both the radial and axial directions of the central axis. The rotor manufacturing method is performed using a magnet support mechanism. The magnet support mechanism has a pair of support surfaces. The pair of support surfaces are inclined so that they move away from each other in the opposing directions as they extend radially outward. The rotor manufacturing method supports the magnets by bringing the circumferential end faces of the magnets into contact with the pair of support surfaces. Furthermore, the rotor manufacturing method moves the magnets radially inward by separating the pair of support surfaces in the opposing direction FD, thereby attaching them to the outer circumferential surface of the rotor core. [Brief explanation of the drawing]

[0007] [Figure 1] A schematic cross-sectional view of a rotor manufacturing apparatus according to an embodiment. [Figure 2] A perspective view of the magnet support mechanism of the rotor manufacturing apparatus according to the embodiment. [Figure 3] A schematic diagram showing the magnet mounting step of the rotor manufacturing method according to the embodiment. [Figure 4] A schematic diagram showing the magnet mounting step of the rotor manufacturing method according to the embodiment. [Figure 5] A cross-sectional view along the central axis of a rotating electric machine equipped with a rotor manufactured by the manufacturing method according to the embodiment. [Figure 6] A cross-sectional view perpendicular to the central axis of a rotating electric machine equipped with a rotor manufactured by the manufacturing method according to the embodiment. [Figure 7] A perspective view of a magnet used in the manufacturing method of a rotor according to an embodiment. [Figure 8] A schematic diagram showing an example of an aircraft configuration. [Modes for carrying out the invention]

[0008] The rotor manufacturing apparatus and rotor manufacturing method of the embodiment will be described below with reference to the drawings. The rotor manufacturing apparatus, the rotors manufactured by this apparatus, and the rotating electric machine having said rotors can be modified in design as appropriate to meet specifications. The shapes of each component included in the rotor manufacturing apparatus, the rotors manufactured thereby, and the rotating electric machine can be arbitrarily changed, and the shapes and quantities shown in the drawings are merely examples. Similarly, the rotor manufacturing method can be modified as appropriate in terms of each process. The configuration of each process included in the rotor manufacturing apparatus can be arbitrarily changed, and the state shown in the drawings is merely an example.

[0009] In the following explanation, the direction parallel to the central axis J will simply be called the "axial direction," the radial direction centered on the central axis J will simply be called the "radial direction," and the circumferential direction centered on the central axis J will simply be called the "circumferential direction θ." In addition, the axial direction AD, radial direction RD, and circumferential direction θ will be shown in each figure as needed. In each figure, the direction in which the arrow for the axial direction AD points will be called the "one side of the axial direction (+AD)," and the opposite direction will be called the "other side of the axial direction (-AD)."

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

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

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

[0013] The rotor core support 62 supports the rotor core 27. The rotor core support 62 has, for example, a pair of support columns 62a fixed to the base 61. The pair of support columns 62a extend upward from the base 61. The pair of support columns 62a are positioned on both sides of the axial direction AD of the rotor core 27. Each of the pair of support columns 62a is provided with a retaining hole 62h that penetrates through the axial direction AD. The shaft 21 is inserted into the retaining hole 62h. In this way, the pair of support columns 62a support both ends of the shaft 21.

[0014] For example, a locking mechanism (not shown) that restricts the rotation of the shaft 21 around the central axis J may be provided on one of the support portions 62a. In this case, the rotor core support portion 62 has the locking mechanism. The rotor core support portion 62 can rotate the shaft 21 around the central axis J by releasing the locking mechanism. The rotor core support portion 62 can fix the rotor core 27 in a state where a desired position on the outer peripheral surface 27a of the rotor core 27 is directed toward the magnet support mechanism 70. Note that the locking mechanism is not necessarily provided, and instead of the locking mechanism, the rotation of the rotor may be suppressed by a jig or the like from the outside and fixed at a predetermined position.

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

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

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

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

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

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

[0021] In this specification, the angle formed between the pair of support surfaces 71f is defined as the support surface angle α. The pair of support surfaces 7l f can approach and separate from each other in the facing direction FD by the function of the drive unit 80 described later. The support surface angle α is preferably a constant angle regardless of the approach and separation of the support surfaces zl f.

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

[0023] With a magnet 25m sandwiched between a pair of support surfaces 71f, when the support surfaces 71f separate, the end face 25a of the magnet 25m in the circumferential direction θ slides downward along the support surfaces 71f. As the pair of support surfaces 71f separate, the magnet 25m moves inward in the radial direction RD while maintaining its orientation.

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

[0025] As shown in Figure 2, the distance between the support surfaces 71f at one end of the axial direction AD is defined as the first distance d1. On the other hand, the distance between the support surfaces 71f at the other end of the axial direction AD is defined as the second distance d2. As the pair of support surfaces 71f increase in distance towards the top, both the first distance d1 and the second distance d2 are the distances between the lower ends of the pair of support surfaces 71f.

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

[0027] Preferably, the surface of the support surface 71f is treated to reduce frictional resistance. For example, the surface treatment can be a treatment that forms a surface film. Alternatively, a film that reduces friction between the support surface 71f and the end face 25a of the magnet 25m may be attached to the surface of the support surface 71f. This helps to prevent damage to the magnet 25m when it slides on the support surface 71f.

[0028] The pair of support members 71 may have, for example, slits extending upward from the lower end of the support surface 71f. In this case, it is preferable that the slits of the pair of support members 71 are offset in axial position AD, and that the pair of support members 71 intersect so that they are inserted into each other's slits as they approach each other. In this case, by having the support members 71 intersect, the magnet support mechanism 70 can further separate the magnet 25m from the rotor core 27. This makes it possible to position the magnet 25m between the pair of support surfaces 71f in a location where the attractive force between the magnet 25m and the rotor core 27 does not reach, thus simplifying the preliminary work.

[0029] As shown in Figure 2, the pair of connecting plate portions 72 are, for example, plate-shaped and aligned with a horizontal plane. The pair of connecting plate portions 72 extend parallel to each other along the axial direction AD. In the following description, when distinguishing between the pair of connecting plate portions 72, the one located on one side of the opposing direction FD will be called the first connecting plate portion 72A, and the other located on the other side of the opposing direction FD will be called the second connecting plate portion 72B. The first connecting plate portion 72A is mounted and fixed to the first support member 71A. On the other hand, the second connecting plate portion 72B is mounted and fixed to the second support member 71B. Furthermore, the first connecting plate portion 72A and the second connecting plate portion 72B are each mounted and fixed to the drive unit 80.

[0030] As will be explained later with reference to Figure 4, each of the pair of connecting plate sections 72 has a removable spacer (adjustment section) 72s. The height of the support member 71 can be adjusted by placing a plate-shaped spacer 72s between the connecting plate section 72 and the support member 71. Note that the spacer 72s is just one example of an adjustment section for adjusting the height, and other configurations may be adopted.

[0031] As shown in Figure 2, the drive unit 80 includes, for example, a slide mechanism 85 and a screw drive mechanism 81. The drive unit 80 moves a pair of support members 71 closer to and further apart from each other in the opposing direction FD.

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

[0033] The screw drive mechanism 81 includes, for example, a rotating shaft 82, a pair of bearing portions 83, and a pair of nut portions 84. The rotating shaft 82 extends along the opposing direction FD. The outer circumference of the rotating shaft 82 is provided with, for example, a first male threaded portion 82a and a second male threaded portion 82b. The first male threaded portion 82a and the second male threaded portion 82b are arranged side by side along the length of the rotating shaft 82. The first male threaded portion 82a and the second male threaded portion 82b are reverse threads. That is, one of the first male threaded portion 82a and the second male threaded portion 82b is a right-hand thread and the other is a left-hand thread.

[0034] An actuator, for example, not shown, is connected to one end of the rotating shaft 82. The rotating shaft 82 is rotated by the actuator. Alternatively, instead of an actuator, a handle may be provided at one end of the rotating shaft 82. In this case, the worker assembling the magnet 25m rotates the rotating shaft 82 using the handle.

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

[0036] The nut portion 84 is, for example, block-shaped. The nut portion 84 is provided with a threaded hole that penetrates in the opposing direction FD. A female thread is formed on the inner circumferential surface of this threaded hole. The female threads of the pair of nut portions 84 are reverse threads. Of the pair of nut portions 84, the first male threaded portion 82a is inserted into one, and the second male threaded portion 82b is inserted into the other. For the first male threaded portion 82a and the second male threaded portion 82b and the pair of nut portions 84, for example, trapezoidal screws can be used. Of the pair of nut portions 84, the one located on one side in the opposing direction FD is fixed to the other axial end (-AD) of the first connecting plate portion 72A. The other nut portion 84 located on the other side in the opposing direction FD is fixed to the other axial end (-AD) of the second connecting plate portion 72B.

[0037] The sliding mechanism 85 includes, for example, a rail section 85a and a pair of block sections 85b. The rail section 85a extends along the opposing direction FD. The pair of block sections 85b are assembled to the rail section 85a in a state aligned along the opposing direction FD. Each of the pair of block sections 85b is independently slidable along the rail section 85a along the opposing direction FD. One of the pair of block sections 85b, located on one side of the opposing direction FD, is fixed to the axial end (+AD) of the first connecting plate section 72A. The other block section 85b, located on the other side of the opposing direction FD, is fixed to the axial end (+AD) of the second connecting plate section 72B.

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

[0039] The pair of support members 71 move parallel to each other along the opposing direction FD. As a result, the support surfaces 71f of the pair of support members 71 can move closer to and further apart from each other while maintaining the support surface angle α (see Figure 3). As the pair of support surfaces 71f move closer to and further apart, the gap between the pair of support surfaces 71f narrows or widens. Consequently, the magnet 25m sandwiched between the pair of support surfaces 71f can move radially along the central axis J.

[0040] As shown in Figure 3, the pressurizing mechanism 64 applies pressure to the outer surface 25c of the magnet 25m, which is supported by the magnet support mechanism 70, in the radial direction RD of the central axis J. This causes the pressurizing mechanism 64 to press the magnet 25m against a pair of support surfaces 71f. The pressurizing mechanism 64 includes, for example, a pressurizing section 64a, a spring section 64b, and a lifting section (not shown).

[0041] The pressurizing portion 64a has, for example, a contact surface 64c that curves along the outer surface 25c of the magnet 25m. A material with a high modulus of elasticity, such as rubber or elastomer resin, may be attached to the contact surface 64c. This prevents the outer surface of the magnet 25m from receiving a large localized force from the pressurizing mechanism 64, thereby preventing damage to the magnet 25m.

[0042] The spring portion 64b applies a force to the pressurizing portion 64a toward the outer surface 25c of the magnet 25m. A lifting portion (not shown) moves the pressurizing portion 64a and the spring portion 64b vertically up and down. The lifting portion can also be driven in conjunction with the screw drive mechanism 81 of the magnet support mechanism 70. That is, the lifting portion can apply a constant pressure to the outer surface 25c of the magnet 25m at all times by moving the pressurizing portion 64a and the spring portion 64b up and down in accordance with the height of the magnet 25m, which moves up and down according to the proximity of the pair of support surfaces 71f. This allows a constant frictional force to be applied between the circumferential end face 25a of the magnet 25m and the support surface 71f of the magnet support mechanism 70, and allows the magnet 25m to move smoothly inward in the radial direction RD as the pair of support members 71 move.

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

[0044] As shown in Figure 1, the pair of backing plates 63 have a backing surface 63f. In addition to the backing surface 63f, the pair of backing plates 63 may also have a guide surface 63a. The backing surface 63f is perpendicular to the axial direction AD. The backing surface 63f extends in the vertical direction (i.e., the radial direction RD). The pair of backing surfaces 63f face each other in the axial direction AD. The distance between the pair of backing surfaces 63f is approximately the same as or slightly larger than the axial direction AD of the magnet 25m. According to this embodiment, the magnet 25m is positioned in the axial direction AD by being placed between the pair of backing surfaces 63f. This makes it possible to mount the magnet 25m to the rotor core 27 in a positional manner in the axial direction AD.

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

[0046] Figure 4 is a schematic diagram of the rotor manufacturing apparatus 60 viewed from the axial direction, similar to Figure 3. Figures 3 and 4 are diagrams illustrating the procedure for manufacturing the rotor 20. Here, we will describe an example of the magnet attachment step, in which a magnet 25m is attached to the outer circumferential surface 27a of the rotor core 27, among the various steps in the manufacturing process of the rotor 20.

[0047] In the following description, when distinguishing between the multiple magnets 25m provided on the rotor 20 whose magnetization directions are opposite to each other in the radial direction RD, these will be referred to as the first magnet 25s and the second magnet 25n, respectively. Here, the first magnet 25s is assumed to be a magnet that forms a south pole outside the radial direction RD, and the second magnet 25n is assumed to be a magnet that forms a north pole outside the radial direction RD. Furthermore, when the first magnet 25s and the second magnet 25n are not distinguished from each other, they will simply be referred to as magnets 25m.

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

[0049] Figure 3 shows the first procedure. In the magnet mounting process, adhesive is applied to the outer circumferential surface 27a of the rotor core 27, the inner circumferential surface of the magnet 25m, or both. Also, as shown in Figure 1, in the magnet mounting process, the rotor core 27 is supported and fixed by the rotor core support part 62. This restricts the movement of the rotor core 27 in the axial direction AD and the circumferential direction θ.

[0050] As shown in Figure 3, in the magnet mounting process, first the magnet 25m is placed between a pair of support surfaces 71f. Then, the circumferential end faces 25a of the magnet 25m are brought into contact with the pair of support surfaces 71f. In this way, the pair of support surfaces 71f support the magnet 25m.

[0051] Next, the magnet 25m is moved inward in the radial direction RD by separating the pair of support surfaces 71f from each other in the opposing direction FD. The magnet support mechanism 70 further widens the gap between the pair of support members 71 while the magnet 25m is in contact with the outer circumferential surface 27a of the rotor core 27. This separates the pair of support surfaces 71f from the magnet 25m and releases the support of the magnet 25m. An attractive force acts between the magnet 25m and the rotor core 27. As a result, surface pressure acts between the inner surface of the magnet 25m and the outer circumferential surface 27a of the rotor core 27, and the magnet 25m adheres to the outer circumferential surface 27a of the rotor core 27 without any gaps.

[0052] In the first step, the process of attaching the first magnet 25s is repeated for the number of first magnets 25s, thereby attaching multiple first magnets 25s to the outer circumferential surface 27a of the rotor core 27. After attaching one first magnet 25s, the rotor core 27 is rotated around the central axis J. This allows multiple first magnets 25s to be arranged in a circumferential direction on the outer circumferential surface 27a of the rotor core 27. When rotating the rotor core 27, for example, the locking mechanism that locks the rotation of the rotor core by the rotor core support part 62 shown in Figure 1 is released, the rotor core 27 is rotated by a predetermined angle, and then the locking mechanism is activated again.

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

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

[0055] As shown in Figure 4, in the second step of magnet mounting, the magnet 25m is moved inward in the radial direction RD by separating the pair of support surfaces 71f from each other in the opposing direction FD. The magnet support mechanism 70 further widens the gap between the pair of support members 71 while the magnet 25m is as close as possible to the outer circumferential surface 27a of the rotor core 27. This separates the pair of support surfaces 71f from the magnet 25m and releases the support of the magnet 25m. The magnet 25m moves away from the support surfaces 71f and is attracted to the outer circumferential surface 27a of the rotor core 27.

[0056] Although not shown in the diagram, in the second step, the process of attaching the second magnet 25n is repeated for the number of second magnets 25n, similar to the first step, thereby attaching the second magnets 25n to the outer surface 27a of the rotor core 27. The adhesive may be cured each time a magnet is attached, or it may be cured after the first step, or after the second step, or after both the first and second steps. As a result, all the magnets 25m are attached to the outer surface 27a of the rotor core 27. Furthermore, the manufacturing process of the rotor 20 is completed by attaching a cover to the outer surface 25c of the magnets 25m.

[0057] The configuration of the rotor manufacturing apparatus 60 and the method for manufacturing the rotor 20 according to this embodiment, and their effects, are summarized below. The rotor manufacturing apparatus 60 of this embodiment is a rotor manufacturing apparatus (60) that attaches a magnet 25m to the outer circumferential surface 27a of a rotor core 27 that extends axially around a central axis J. The rotor manufacturing apparatus 60 comprises a rotor core support section 62 and a magnet support mechanism 70. The rotor core support section 62 supports the rotor core 27. The magnet support mechanism 70 supports the magnet 25m outside the radial direction RD of the rotor core 27. The magnet support mechanism 70 comprises a pair of support members 71 and a drive unit 80. The pair of support members 71 face each other in the opposing direction FD which is perpendicular to both the radial direction RD and the axial direction AD. The magnet 25m is placed between the pair of support members 71. The drive unit 80 moves the pair of support members 71 closer to and further apart from each other in the opposing direction FD. The pair of support members 71 each have a support surface 71f. The pair of support surfaces 71f face each other in the opposing direction FD. The pair of support surfaces 71f are in contact with the end faces 25a of the magnet 25m in the circumferential direction θ. The pair of support surfaces 71f are inclined so that they move away from each other in the opposing direction FD as they move outward in the radial direction RD.

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

[0059] In the rotor 20 manufactured by the manufacturing method of this embodiment, a samarium cobalt (SmCo) magnet is used as the magnet 25m. Compared to other common rare-earth magnets such as neodymium magnets, samarium cobalt magnets have superior heat resistance and are known to maintain high magnetic properties even at high temperatures of 150°C or higher. When the rotating electric machine 1 is mounted on a moving object such as an aircraft 90, miniaturization and weight reduction are pursued. For this reason, it is difficult to adopt complex or large cooling and heat dissipation structures in the rotating electric machine 1. According to this embodiment, by adopting a samarium cobalt magnet as the magnet 25m, it is possible to construct a rotating electric machine 1 that exhibits sufficient torque performance even when the magnet 25m is hot. As a result, the cooling and heat dissipation structures of the rotating electric machine 1 can be simplified. However, on the other hand, samarium cobalt magnets are prone to damage when subjected to impact. Also, samarium cobalt magnets are difficult to magnetize by post-magnetization, such as magnetizing them after they have been assembled to the rotor core. Therefore, when using a samarium-cobalt magnet as the magnet 25m of the rotor 20, it is necessary to attach the magnetized magnet 25m to the outer surface of the rotor core without subjecting it to impact and while maintaining high dimensional accuracy. According to the rotor manufacturing apparatus 60 of this embodiment, the magnet 25m can be attached to the rotor core 27 without damaging the magnet 25m, which is made of a samarium-cobalt magnet that is prone to damage from impact.

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

[0061] This configuration stabilizes the contact between the end face 25a of the magnet 25m and the support surface 71f when the magnet 25m is moved radially RD, thereby suppressing rattling of the magnet 25m. This makes it possible to smoothly attach the magnet 25m to the outer circumferential surface 27a of the rotor core 27.

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

[0063] With this configuration, when moving the magnet 25m radially RD, the gap between the axial end of the support surface 71f (either one or the other) and the end face 25a of the magnet 25m can be made sufficiently small, about 10 μm (more preferably about 5 μm). This suppresses rattling of the magnet 25m when it moves, and allows the magnet 25m to be smoothly attached to the outer circumferential surface 27a of the rotor core 27.

[0064] The rotor manufacturing apparatus 60 of this embodiment may be equipped with a pair of backing plates 63. The pair of backing plates 63 are located on both sides of the axial direction AD of the magnet 25m supported by the magnet support mechanism 70. Each of the pair of backing plates 63 has a backing surface 63f. The pair of backing surfaces 63f face each other. The pair of backing surfaces 63f are perpendicular to the axial direction AD.

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

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

[0067] When attaching the magnets 25m to the outer circumferential surface 27a of the rotor core 27, it is preferable to attach all the magnets of one pole (e.g., the first magnet 25s) first, and then all the magnets of the other pole (e.g., the second magnet 25n), in order to suppress repulsion between the magnets 25m. With the above configuration, the rotor manufacturing apparatus 60 has a spacer 72s, so that when attaching the magnets of one pole, the support member 71 can be brought closer to the outer circumferential surface 27a of the rotor core 27. Also, when attaching the magnets of the other pole, they can be positioned between the magnets 25m of the already attached pole, while maintaining a certain distance from the outer circumferential surface 27a of the rotor core 27, and avoiding contact with the magnets 25m.

[0068] The rotor manufacturing apparatus 60 of this embodiment may be equipped with a pressurizing mechanism 64. The pressurizing mechanism 64 presses the magnet 25m, which is supported by the magnet support mechanism 70, against a pair of support surfaces 71f.

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

[0070] In the rotor manufacturing apparatus 60 of this embodiment, the drive unit 80 can move a pair of support members 71 in opposite directions along the opposing direction FD at the same speed.

[0071] This configuration allows the magnet 25m to be brought close to the outer surface 27a of the rotor core 27 without moving it in the circumferential direction θ. Therefore, when bringing the magnet 25m close to the rotor core 27, it is easier to maintain a constant position of the magnet 25m, and the magnet 25m can be smoothly attached to the outer surface 27a of the rotor core 27.

[0072] The manufacturing method for the rotor 20 of this embodiment involves attaching a magnet 25m to the outer circumferential surface 27a of a rotor core 27 that extends in the axial direction AD with respect to the central axis J. In this embodiment, the opposing direction FD is defined as the direction perpendicular to both the radial direction RD and the axial direction AD of the central axis J. The manufacturing method for the rotor 20 is performed using a magnet support mechanism 70. The magnet support mechanism 70 has a pair of support surfaces 71f. The pair of support surfaces 71f are inclined to move away from each other in the opposing direction FD as they move outward from the radial direction RD. The manufacturing method for the rotor 20 supports the magnet 25m by bringing the end faces 25a of the magnet 25m in the circumferential direction θ into contact with the pair of support surfaces 71f. Furthermore, the manufacturing method for the rotor 20 moves the magnet 25m inward from the radial direction RD by separating the pair of support surfaces 71f from each other in the opposing direction FD, thereby attaching it to the outer circumferential surface 27a of the rotor core 27.

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

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

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

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

[0077] The housing 10 includes, for example, a housing body 12 that extends along the axial direction AD and surrounds the stator 30 from the outside in the radial direction RD, bearing holders 11 fixed to one axial end (+AD) and the other axial end (-AD) of the housing body 12, and heat dissipation fins 12f.

[0078] The bearing holder 11 is, for example, a disc shape centered on the central axis J. A pair of bearing holders 11 each cover the openings on both axial sides of the housing body 12. The bearing holders 11 are fixed, for example, to the end faces of the housing body 12 facing the axial direction AD using bolts (not shown). The housing body 12 holds the bearing B in its central part. The bearing B rotatably supports the shaft 21 of the rotor 20.

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

[0080] The rotor 20 is rotatably supported in the housing 10 about its central axis J. The rotor 20 comprises a shaft 21 having the central axis J, a hub member 23, a rotor core 27, a magnet unit 25, and a cover 26.

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

[0082] The rotor core 27 is made of a magnetic material. The rotor core 27 is, for example, a laminated steel sheet formed by stacking multiple electromagnetic steel sheets in the axial direction AD. The rotor core 27 extends in the axial direction AD with respect to the central axis J. The rotor core 27 in Figure 6 is, for example, cylindrical. A magnet unit 25 is arranged on the outer circumferential surface 27a of the rotor core 27.

[0083] The magnet unit 25 is, for example, annular in shape. The magnet unit 25 can be fixed to the outer surface of the rotor core 27 by bonding means such as adhesive. The rotor 20 in Figure 6 is a surface magnet type in which the magnet unit 25 is magnetically directly opposite the stator 30.

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

[0085] As shown in Figure 6, the magnet 25m extends in an arc shape centered on the central axis J when viewed from the axial direction AD. The magnet 25m is also plate-shaped with the radial direction RD as the thickness direction. The inner surface of the magnet 25m facing inward along the radial direction RD is bonded and fixed to the outer surface of the rotor core 27. The outer surface 25c of the magnet 25m facing outward along the radial direction RD is covered by a cylindrical cover 26. The cover 26 surrounds the magnet unit 25 and prevents the multiple magnets 25m from detaching from the rotor core 27. The cover 26 is made of a material that does not easily affect the magnetic force of the magnet unit 25.

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

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

[0088] As shown in Figure 7, the magnet 25m is constructed by joining multiple elemental magnets 25e. Therefore, compared to the case where the magnet is made up of a single sintered magnet, the value of the eddy current flowing through each elemental magnet 25e can be reduced, and the eddy current loss generated in the magnet 25m as a whole can be reduced. This suppresses the heat generated in the magnet 25m due to the eddy currents generated in the magnet 25m, reduces the decrease in the magnetic force of the magnet 25m, and improves the torque performance of the rotating electric machine 1.

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

[0090] In the example shown in Figure 7, the element magnet 25e is made of a samarium-cobalt magnet. That is, the magnet 25m in Figure 7 is a samarium-cobalt magnet. Compared to other common rare-earth magnets such as neodymium magnets, samarium-cobalt magnets have superior heat resistance and are known to maintain high magnetic properties even at high temperatures above 150°C, where the magnetic force of neodymium magnets decreases significantly. By using a samarium-cobalt magnet as magnet 25m, it is possible to construct a rotating electric machine 1 that exhibits sufficient torque performance even when magnet 25m is at high temperatures.

[0091] The above-mentioned rotating electric machine can be mounted on various propulsion systems, such as automobiles, trains, and aircraft. Figure 8 is a schematic diagram of an aircraft 90 as an example of a propulsion system on which the rotating electric machine 1 is mounted. The aircraft 90 is a hybrid aircraft that is propelled by a combination of jet engines 91 and rotating electric machines 1. The aircraft 90 has a pair of jet engines 91 and four rotating electric machines 1. The jet engines 91 are mounted on the main wings 98. The jet engines 91 generate thrust by exhausting to the rear.

[0092] The four rotating electric machines 1 are classified into two power-generating rotating electric machines 1A and two drive-generating rotating electric machines 1B. Each power-generating rotating electric machine 1A is connected to the main shaft of the jet engine 91. The power-generating rotating electric machines 1A generate electricity using the jet engine 91. Meanwhile, the drive-generating rotating electric machines 1B are positioned below the vertical stabilizer 99. The drive-generating rotating electric machines 1B generate thrust by rotating the propulsion fan 93, which sends air backward. The drive-generating rotating electric machines 1B are driven by the electricity generated by the power-generating rotating electric machines 1A. If the power-generating rotating electric machines 1A generate excess electricity, this electricity may be used to charge a battery and use when necessary.

[0093] While several embodiments of the present invention have been described, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These embodiments can be carried out in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims and their equivalents. [Explanation of Symbols]

[0094] 20...Rotor, 25a...End face, 25a...Both end faces, 25m...Magnet, 27...Rotor core, 27a...Outer circumference, 60...Rotor manufacturing device, 62...Rotor core support part, 63...Plate part, 63f...Surface, 64...Pressure mechanism, 70...Magnet support mechanism, 71...Support member, 71f...Support surface, 72s...Spacer (adjustment part), 80...Drive unit, AD...Axial direction, FD...Opposite direction, J...Central axis, RD...Radial direction, α...Support surface angle, θ...Circumferential direction, φ...Magnet end face angle

Claims

1. A rotor manufacturing apparatus for attaching magnets to the outer surface of a rotor core that extends axially with respect to a central axis, A rotor core support portion that supports the rotor core, The rotor core is supported by a magnet support mechanism that supports the magnet on the radially outer side of the rotor core, The aforementioned magnet support mechanism is A pair of support members that face each other in opposing directions perpendicular to both the radial and axial directions, with the magnet positioned between them, The drive unit moves the pair of support members in parallel along the opposing directions, causing them to move closer to and further apart from each other in those opposing directions. The pair of support members each have a support surface that faces each other in the opposing direction and contacts the circumferential end surface of the magnet, The pair of support surfaces are inclined in directions that move away from each other in the opposing directions as they extend outward in the radial direction. Rotor manufacturing equipment.

2. The angle between the two end faces of the magnet in the circumferential direction is defined as the magnet end face angle. The angle between the pair of support surfaces is defined as the support surface angle. The support surface angle is maintained at ±10° or less with respect to the magnet end surface angle, regardless of the distance between the pair of support members. The rotor manufacturing apparatus according to claim 1.

3. The absolute value of the difference between the distance between the support surfaces at one end in the axial direction and the distance between them at the other end in the axial direction remains 10 μm or less, regardless of the distance between the pair of support members. The rotor manufacturing apparatus according to claim 1.

4. The magnet support mechanism comprises a pair of backing plates located on both sides in the axial direction of the magnet, The pair of backing plates each have a backing surface that faces each other and is perpendicular to the axial direction. The rotor manufacturing apparatus according to claim 1.

5. The magnet support mechanism has an adjustment section that changes the radial distance between the pair of support members with respect to the central axis. The rotor manufacturing apparatus according to claim 1.

6. The magnets supported by the magnet support mechanism are provided with a pressurizing mechanism that presses the magnets against the pair of support surfaces. The rotor manufacturing apparatus according to claim 1.

7. The drive unit moves the pair of support members in opposite directions along the opposing direction at the same speed. The rotor manufacturing apparatus according to claim 1.

8. A method for manufacturing a rotor, comprising attaching magnets to the outer surface of a rotor core that extends axially with respect to a central axis, The directions perpendicular to both the radial and axial directions of the central axis are considered as opposing directions. A magnet support mechanism is used which has a pair of support surfaces that are inclined in directions that move away from each other in the opposing direction as they extend outward in the radial direction, The magnet is supported by bringing the circumferential end faces of the magnet into contact with the pair of support surfaces. By separating the pair of support surfaces in the opposing direction, the magnet is moved inward in the radial direction and attached to the outer circumferential surface of the rotor core. A method for manufacturing a rotor.

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