Rotor, rotary electrical machine, rotor manufacturing method, component, and component manufacturing method

Abstract

Provided is a rotor (2) that comprises: a rotor core (20), in which a rotating shaft (1) is disposed to serve as the rotational center for a rotary electrical machine (100); and a magnet (3) disposed in the rotor core (20). The rotor core (20) comprises: a press-fit hole (21) into which the rotating shaft (1) is inserted and fixed in the axial direction (Y); a through hole (6) that is formed at least at one location in the circumferential direction and that passes, in the axial direction (Y), between the press-fit hole (21) and an outer circumferential surface (22) of the rotor core (20); and a positioning hole portion (4), which is located in one part in the axial direction (Y) of the through hole (6) and which has a smaller diameter (W2) than the minimum diameter (W1) of the through hole (6).

Description

Rotor, rotating electric machine, rotor manufacturing method, component, and component manufacturing method

[0001] The present application relates to a rotor, a rotating electric machine, a rotor manufacturing method, a component, and a component manufacturing method.

[0002] A rotor for a conventional rotating electric machine is formed by fixing at least one rotor core to a rotating shaft and assembling magnets circumferentially to the outer circumferential surface or inside of the rotor core. The fixing of the rotor core to the rotating shaft is generally performed by shrink fitting or press fitting, and positioning of the phase and other factors is required depending on the shapes of the two parts. For example, a rotor with a step-skew structure has two or more rotor cores arranged along the axial direction of the rotating shaft, and the rotor cores arranged at each position are fixed to the rotating shaft with a circumferential offset by a predetermined phase angle (skew angle). To form the skew angle, the rotor cores arranged at each position have positioning holes, and the rotor cores are positioned by passing positioning pins through the positioning holes, and then the rotating shaft is fixed (see, for example, Patent Document 1).

[0003] Special Publication No. 2022-500984

[0004] In conventional rotors, if positioning holes in the rotor core are installed in the entire axial direction, the dimensional tolerance of the positioning holes is likely to deteriorate due to factors such as machining accuracy, and in order to avoid interference between the positioning holes and the positioning pins, the size of the positioning pins must be set small, which creates the problem of deteriorating positioning accuracy.

[0005] The present application discloses technology for solving the above-mentioned problems, and aims to provide a rotor, a rotating electric machine, a rotor manufacturing method, a component, and a component manufacturing method that can improve the positioning accuracy in the manufacture of rotors and components.

[0006] The present application discloses a rotor including a rotor core having a rotating shaft that serves as the center of rotation of a rotating electric machine, and a magnet installed in the rotor core, wherein the rotor core has a press-fit hole for inserting and fixing the rotating shaft in the axial direction, one or more through holes formed circumferentially between the press-fit hole and the outer peripheral surface of the rotor core, and a positioning portion in an axial portion of the through hole having a diameter smaller than that of the remaining portion of the through hole. The present application also discloses a rotating electric machine including the above-described rotor and a stator having a plurality of windings and disposed opposite the outer peripheral side of the rotor with a predetermined air gap between them. The present application also discloses a method for manufacturing a rotor, comprising the steps of: inserting a positioning pin having a maximum diameter insertable into the positioning portion into the through hole having the positioning portion of the rotor core; press-fitting the rotating shaft into the press-fit hole of the rotor core; and then removing the positioning pin from the rotor core. The present application also discloses a component that is positioned relative to a manufacturing device, the component having a through hole into which a positioning pin installed in the manufacturing device can be inserted, and the through hole has a positioning portion in a portion of the through hole in the penetrating direction, the positioning pin having a diameter smaller than the diameter of the other portion of the through hole. The present application also discloses a method for manufacturing a component, the method comprising: inserting a positioning pin having a maximum diameter that can be inserted into the positioning portion into the through hole having the positioning portion of the component; performing a manufacturing process of the component using the manufacturing device; and then removing the positioning pin from the component.

[0007] According to the rotor, rotating electric machine, rotor manufacturing method, component, and component manufacturing method disclosed in the present application, it is possible to improve the positioning accuracy in manufacturing rotors and components.

[0008] 16 is a longitudinal sectional view showing the configuration of a rotating electric machine according to embodiment 1. FIG. 17 is a longitudinal sectional view showing the configuration of a rotor of the rotating electric machine shown in FIG. 1. FIG. 18 is a longitudinal sectional view showing a manufacturing method of the rotor shown in FIG. 2. FIG. 19 is a longitudinal sectional view showing another configuration of the rotor of the rotating electric machine shown in FIG. 1. FIG. 20 is a longitudinal sectional view showing a manufacturing method of the rotor shown in FIG. 5. FIG. 21 is a longitudinal sectional view showing the configuration of a rotor according to embodiment 2. FIG. 22 is a longitudinal sectional view showing a manufacturing method of the rotor shown in FIG. 7. FIG. 23 is a plan view showing the configuration of core pieces of the rotor shown in FIG. 7. FIG. 24 is a plan view showing the configuration of core pieces of the rotor shown in FIG. 7. FIG. 25 is a longitudinal sectional view showing the configuration of a rotor core of a rotor according to embodiment 3. FIG. 26 is a longitudinal sectional view showing the configuration of a rotor core of a rotor according to embodiment 4. FIG. 27 is a longitudinal sectional view showing the configuration of a rotor core of a rotor according to embodiment 5. FIG. 28 is a longitudinal sectional view showing a state in which a positioning pin is inserted into the rotor core shown in FIG. 13. FIG. 29 is a longitudinal sectional view showing the configuration of a rotor core of another rotor according to embodiment 6. FIG. 29 is a longitudinal sectional view showing a state in which a positioning pin is inserted into the rotor core shown in FIG. 16. FIG. 29 is a longitudinal sectional view showing the configuration of a rotor core of another rotor according to embodiment 6. FIG. 29 is a longitudinal sectional view showing the configuration of a rotor core of another rotor according to embodiment 6. 23A is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20; FIG. 23B is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20; FIG. 23C is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20; FIG. 23D is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20; and FIG. 23E is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20. FIG. 23B is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20; FIG. 23C is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20; FIG. 23D is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20; and FIG. 23E is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 20.Figure 27A is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 24, Figure 27B is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 24, Figure 27C is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 24, Figure 27D is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 24, and Figure 27E is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 24. A longitudinal sectional view showing a state in which a positioning pin has been inserted into the rotor core shown in Figure 24. A plan view showing a state in which a positioning pin has been inserted into the rotor core shown in Figure 25. A longitudinal sectional view showing the configuration of the rotor core of a rotor according to embodiment 9. A plan view showing the configuration of the rotor core shown in Figure 30. A plan view showing the configuration of the core pieces of the rotor core shown in Figure 30. Figure 33A is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 30, Figure 33B is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 30, Figure 33C is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 30, Figure 33D is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 30, and Figure 33E is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 30. A longitudinal sectional view showing a state in which a positioning pin has been inserted into the rotor core shown in Figure 30. A plan view showing a state in which a positioning pin has been inserted into the rotor core shown in Figure 31. A longitudinal sectional view showing the configuration of the rotor core of the rotor according to embodiment 10. A plan view showing the configuration of the rotor core shown in Figure 36. A plan view showing the configuration of the core pieces of the rotor core shown in Figure 36. Figure 39A is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 36, Figure 39B is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 36, Figure 39C is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 36, Figure 39D is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 36, and Figure 39E is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 36. A longitudinal sectional view showing a state in which a positioning pin has been inserted into the rotor core shown in Figure 36. A plan view showing a state in which a positioning pin has been inserted into the rotor core shown in Figure 37. A perspective view showing the configuration of the positioning pin shown in Figure 36. A longitudinal sectional view showing the configuration of the rotor core of a rotor according to embodiment 11. A plan view showing the configuration of the rotor core shown in Figure 43. A plan view showing the configuration of the core pieces of the rotor core shown in Figure 43.51A is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 43. FIG. 51B is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51C is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51D is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51E is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51A is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48, FIG. 51B is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48, FIG. 51C is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48, FIG. 51D is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48, and FIG. 51E is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51B is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51E is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51C is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51D is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48. FIG. 51E is a plan view showing the configuration of the core pieces of the rotor core shown in FIG. 48.

[0009] In the following description, the axial direction of the rotating shaft 1, which is the center of rotation of the rotating electric machine 100, is referred to as the axial direction Y. Therefore, this direction is the same for other parts constituting the rotating electric machine 100, and the description will be based on this direction. Furthermore, here, the side where insertion of the rotating shaft 1 into the rotor core 20 starts is illustrated as the press-fitting start side Y1, and the receiving side of the manufacturing device for the rotating shaft 1 is illustrated as the receiving surface side Y2.

[0010] Embodiment 1. Figure 1 is a longitudinal cross-sectional view showing the configuration of a rotating electric machine according to embodiment 1. Note that Figure 1 shows a longitudinal cross-section of a portion where a through hole 6, which will be described later, is not formed. Figure 2 is a longitudinal cross-sectional view showing the configuration of a rotor for the rotating electric machine shown in Figure 1. Figures 3 and 4 are longitudinal cross-sectional views showing a method for manufacturing the rotor shown in Figure 2. Figure 5 is a longitudinal cross-sectional view showing another configuration of the rotor for the rotating electric machine shown in Figure 1. Figure 6 is a longitudinal cross-sectional view showing a method for manufacturing the rotor shown in Figure 5.

[0011] As shown in Fig. 1, the rotating electric machine 100 includes a stator 8 and a rotor 2 housed within a motor case 10. The rotating electric machine 100 is used, for example, as an electric power steering motor used in an automobile or the like. This is because the present application can be used for mass-produced rotating electric machines, and the effects of the present application are particularly significant for electric power steering motors, which are in high demand for products with little variation in performance. Note that in the other embodiments below, the rotating electric machine 100 is also used as an electric power steering motor for an automobile, and therefore, the description thereof will be omitted as appropriate.

[0012] The stator 8 is formed by laminating a plurality of core pieces, which are punched out of sheet material such as electromagnetic steel using a press or the like, in the axial direction Y using caulking or the like, and the coil 9 is wound around the core pieces a predetermined number of times. Furthermore, the stator 8 is fixed to the inner periphery of the motor case 10 by press fitting or the like.

[0013] The rotor 2 includes a rotor core 20, a rotating shaft 1 that serves as the center of rotation of the rotating electric machine 100, and a magnet 3. The rotor core 20 includes a press-fit hole 21 formed in the center and penetrating in the axial direction Y, into which the rotating shaft 1 is press-fitted. The magnet 3 is fixed to an outer peripheral surface 22 of the rotor core 20. Furthermore, the rotor 2 is disposed on the inner peripheral side of the stator 8 via a predetermined gap G, and is configured to be rotatable by rotation of the rotating shaft 1.

[0014] 2 , the rotor core 20 has a through hole 6 formed between the press-fit hole 21 and the outer peripheral surface 22 of the rotor core 20, penetrating in the axial direction Y and at one or more locations in the circumferential direction (here, one location). The through hole 6 has a positioning portion 4 in a portion in the axial direction Y, the positioning portion 4 having a diameter W2 smaller than the diameter W1 of the remaining portion of the through hole 6. Here, the positioning portion 4 is formed at a position on the receiving surface side Y2, which is one end side of the through hole 6 in the axial direction Y. Note that the relationship between the diameter W1 of the remaining portion of the through hole 6 and the diameter W2 of the positioning portion 4 is the same in the following embodiments, and therefore description thereof will be omitted where appropriate.

[0015] Next, a method for manufacturing the rotor of the first embodiment configured as described above will be described with reference to Figures 2 to 4. First, as shown in Figure 3, the positioning pins 5 are inserted into the through holes 6 of the rotor core 20 from the receiving surface side Y2 toward the press-fit start side Y1. The positioning pins 5 have a maximum diameter W3 that can be inserted into the positioning portions 4. The positioning pins 5 are installed on the manufacturing equipment side that manufactures the rotor 2, and are used to position the rotor core 20 relative to the manufacturing equipment when the rotating shaft 1 is inserted into the rotor core 20.

[0016] By inserting the positioning pin 5 into the through hole 6, the positioning pin 5 is restrained by the positioning portion 4 in a plane direction perpendicular to the axial direction Y, so that the positioning of the rotor core 20 in the manufacturing apparatus can be determined. Furthermore, because there is almost no interference between the through hole 6 and the positioning pin 5, there is no need to set the size of the positioning pin 5 to be unduly small.

[0017] Next, as shown in Fig. 4, the rotating shaft 1 is press-fitted from the press-fit start side Y1 to the receiving surface side Y2 into the press-fit hole 21 of the rotor core 20, which has been positioned in the manufacturing device by the positioning pin 5. Next, as shown in Fig. 2, the positioning pin 5 is removed from the through hole 6, completing the installation of the rotating shaft 1 in the rotor core 20.

[0018] In the above example, the positioning portion 4 is formed at a position on the receiving surface side Y2, which is one end side of the through hole 6 in the axial direction Y. However, this is not limited to this. As another example, as shown in Fig. 5, the through hole 6 is provided with the positioning portion 4 in a part of the axial direction Y, here, at a position in the center in the axial direction Y. Therefore, similar to the example shown above, as shown in Fig. 6, when the positioning pin 5 is inserted into the through hole 6, it is restrained by the positioning portion 4, and the position of the rotor core 20 relative to the manufacturing apparatus is determined. Furthermore, the positioning portion 4 can also be formed at another position in the axial direction Y within the through hole 6 other than the examples shown above, and the same effect can be achieved.

[0019] In each example of the first embodiment described above, an example has been shown in which one through hole 6 is formed in the rotor core 20, but this is not limited to this, and two or more through holes 6 may be formed in the circumferential direction, penetrating in the axial direction Y, between the press-fit hole 21 and the outer peripheral surface 22 of the rotor core 20. In this case, it is possible to insert the positioning pins 5 into all of the through holes 6 having positioning portions 4, or to insert the positioning pins 5 into some of the through holes 6 having positioning portions 4. This point is similar in the following embodiments, and therefore description thereof will be omitted as appropriate.

[0020] Furthermore, the number of positioning pins 5 used is not particularly limited. It is possible to use one positioning pin as shown in each example of the first embodiment, or multiple positioning pins 5 when multiple through holes 6 are formed. If a positioning pin 5 is installed in only one through hole 6, there is a possibility that the rotor core 20 will rotate around the positioning pin 5. However, it is important that the rotor core 20 does not move from the state in which it is positioned in a specified position by the positioning pin 5 until the start of press-fitting of the rotating shaft 1. In this manufacturing method, even a single positioning pin 5 is sufficient to define the rotor core 20 in that position. Possible methods for positioning the rotor core 20 in a specified position using the positioning pins 5 include using a robot arm or the like that sets the specified position as coordinate information, or, if performed manually, using a guide jig that regulates the outer peripheral surface 22 or press-fit hole 21 of the rotor core 20.

[0021] Furthermore, in each example of the first embodiment, if the through holes 6 formed in the rotor core 20 cause the rotation of the rotor 2 to become unstable, it may be possible to address this by installing a balancer or the like. This also applies to the following embodiments, and therefore the description thereof will be omitted where appropriate.

[0022] Furthermore, in each example of the first embodiment described above, the positioning pins 5 are inserted into the through holes 6 of the rotor core 20 from the receiving surface side Y2 in the axial direction Y toward the press-fit start side Y1, but this is not limiting, and the positioning pins 5 can also be inserted into the through holes 6 of the rotor core 20 from the press-fit start side Y1 in the axial direction Y toward the receiving surface side Y2, depending on the specifications of the manufacturing device for the rotor 2. This point also applies to the following embodiments, and therefore description thereof will be omitted as appropriate.

[0023] Furthermore, in each example of the first embodiment, a rotor of a rotating electrical machine is shown as an example of a component, but the present invention is not limited to this and can be applied to any component that needs to be positioned relative to a manufacturing device. In this case, the component that needs to be positioned relative to the manufacturing device has, as in the above-described case, a through hole 6 into which a positioning pin 5 installed in the manufacturing device can be inserted, and the through hole 6 has, in part in the penetration direction (the same direction as the axial direction Y), a positioning portion 4 having a diameter W2 that is smaller than the diameter W1 of the other part of the through hole 6.

[0024] The manufacturing method for the part involves inserting a positioning pin 5 having a maximum diameter W3 that can be inserted into the positioning portion 4 into a through hole 6 having the positioning portion 4 of the part, then carrying out a manufacturing process using the part's manufacturing equipment, and then removing the positioning pin 5 from the part. Note that the following embodiments can also be similarly applied to parts that require positioning with respect to the manufacturing equipment, and therefore the description thereof will be omitted where appropriate.

[0025] Furthermore, although an example has been shown in which the length of the positioning pin 5 in the axial direction Y is formed to be longer than the length of the through-hole 6 in the axial direction Y, this is not limited to this, and the length of the positioning pin 5 in the axial direction Y is the minimum required length from the side where the positioning pin 5 is inserted to the position where the nearest positioning portion 4 is formed, and as long as there is this minimum required length, the positioning effect can be achieved. Note that this point is the same in the following embodiments, and therefore description thereof will be omitted as appropriate.

[0026] According to the rotor of the first embodiment configured as above, the rotor includes a rotor core in which a rotating shaft that serves as the rotation center of a rotating electric machine is installed, and a magnet installed in the rotor core, the rotor core includes: a press-fit hole for inserting and fixing the rotating shaft in the axial direction; a through-hole that penetrates axially and is formed in one or more locations in the circumferential direction between the press-fit hole and the outer circumferential surface of the rotor core; and a positioning portion in an axial portion of the through-hole, the diameter of which is smaller than the diameter of the remaining portion of the through-hole. Also, according to the rotating electric machine of the first embodiment configured as above, the rotor includes: the rotor described above; and a stator having a plurality of windings and disposed opposite the outer circumferential side of the rotor with a predetermined air gap between them. Also, according to the method of manufacturing the rotor of the first embodiment performed as above, in the manufacturing method of the rotor described above, a positioning pin having the maximum diameter that can be inserted into the positioning portion is inserted into the through-hole having the positioning portion of the rotor core, and then the rotating shaft is press-fitted into the press-fit hole of the rotor core to install it, and then the positioning pin is removed from the rotor core. The dimensional tolerance of the positioning portion of the rotor core can be reduced, which allows the size of the positioning pin to be set larger, leading to improved positioning accuracy and enabling the assembly of a stator for a rotating electrical machine with reduced performance variation.

[0027] Furthermore, according to the rotor of embodiment 1 configured as described above, the positioning portion is formed at a position on either end face side of the rotor core in the axial direction, so that the positioning portion can be formed easily.

[0028] Furthermore, according to the rotor of the first embodiment configured as described above, the positioning portion is formed at the axial center of the rotor core, which simplifies positioning.

[0029] Furthermore, according to the rotating electric machine of the first embodiment configured as described above, since the rotating electric machine is a motor for an electric power steering of an automobile, it is possible to produce a product with little variation in performance.

[0030] Furthermore, according to the part of embodiment 1 configured as described above, in a part that is positioned relative to a manufacturing device, the part has a through hole into which a positioning pin installed on the manufacturing device can be inserted, and the through hole has a positioning portion in one part of the through hole direction that has a diameter smaller than the diameter of the other part of the through hole. Also, according to the method of manufacturing a part of embodiment 1 performed as described above, in the method of manufacturing a part described above, after the positioning pin having the maximum diameter that can be inserted into the positioning portion of the part is inserted into the through hole having the positioning portion of the part, the manufacturing process of the part is carried out using the manufacturing device, and then the positioning pin is removed from the part. Therefore, the dimensional tolerance of the positioning portion of the part can be reduced, and as this allows the size of the positioning pin to be set larger, which leads to improved positioning accuracy and the production of parts with reduced performance variation.

[0031] In the first embodiment described above, an example was shown in which rotor core 20 was formed as a single structure. However, this is not limiting, and in the following embodiments, an example will be described in which rotor core 20 is formed by stacking multiple core pieces in the axial direction Y. The core pieces are formed, for example, by punching thin plate material such as low-carbon steel using a press or the like. The multiple core pieces are then fixed in the axial direction Y by, for example, crimping or the like. In this way, because the core pieces are formed from thin plate material and stacked while being fixed in the axial direction Y by crimping or the like, there is a possibility that the dimensional tolerance of the positioning portion will deteriorate due to the influence of lamination misalignment, leading to a deterioration in positioning accuracy. In the following embodiments, this problem is further solved.

[0032] Embodiment 2. Fig. 7 is a longitudinal sectional view showing the configuration of a rotor according to embodiment 2. Fig. 8 is a longitudinal sectional view showing a method for manufacturing the rotor shown in Fig. 7. Figs. 9 and 10 are plan views showing the configuration of core pieces of the rotor shown in Fig. 7.

[0033] In the figures, parts that are the same as those in the first embodiment are given the same reference numerals, and their description will be omitted. The rotor core 20 is formed by stacking a plurality of core laminations 200 in the axial direction Y. The plurality of core laminations 200 are fixed between each other in the axial direction Y by, for example, crimping as fixing portions. The rotor core 20 has a plurality of types of core laminations 200, and one type of core lamination 201 shown in FIG. 9 has a through hole 60 that forms the through hole 6. Another type of core lamination 202 shown in FIG. 10 has a positioning hole 40 that forms the positioning portion 4.

[0034] Therefore, the diameter of the through hole 60 is diameter W1, and the diameter of the positioning hole 40 is diameter W2, which has the same relationship as in the first embodiment. In order to distinguish the positioning hole 40 from the through hole 60, the positioning hole 40 is shown with diagonal lines in the plan view. Furthermore, when referring to a core piece without specifying the type, it is referred to as a core piece 200. Furthermore, these points are the same in the following embodiments, so description thereof will be omitted.

[0035] The rotor core 20 is formed by alternately stacking the core pieces 201 and 202 in the axial direction Y, so that a through hole 6 having a positioning portion 4 is formed in every other core piece 200 in the axial direction Y, as shown in Fig. 7. As in the first embodiment, the positioning pin 5 is inserted into the through hole 6, as shown in Fig. 8, and horizontal movement is suppressed by the positioning portion 4. The rotor core 20 can have a smaller number of core pieces 202 having positioning holes 40 than the total number of stacked core pieces 200, thereby suppressing the effects of lamination misalignment and reducing the dimensional tolerance of the positioning portion 4, thereby enabling improved positioning accuracy.

[0036] Here, Figure 7 shows an example in which core pieces 202 having the positioning holes 40 and core pieces 201 having the through holes 60 are stacked alternately in the axial direction Y, but by adjusting the mold configuration and stacking program for press-processing the core pieces 200, the positioning portion 4 in the through holes 6 can be set at any position in the axial direction Y.

[0037] As shown in Figure 10, the positioning holes 40 that become the positioning portions 4 are formed in a circular shape. This facilitates machining with superior precision compared to polygonal shapes, enabling reductions in machining costs. In the case of press machining, the elimination of sharp shapes increases mold rigidity, leading to improved mold life. Furthermore, by making the positioning portions 4 circular, the dimensional items that must be managed during assembly can be minimized, simplifying the assembly of the rotor 2 using the positioning pins 5.

[0038] Although the positioning portion 4 is described as being formed in a circular shape as shown in Figure 10, as long as the size relationship between the positioning hole 40 and the through hole 60, i.e., the through hole 6 and the positioning portion 4, is established, there is no limitation on the shape of the through hole 60, and the through hole 60 may be circular or polygonal.

[0039] The rotor of embodiment 2 configured as described above achieves the same effects as embodiment 1 above, and in addition, the rotor core is formed by stacking multiple core pieces in the axial direction, and the multiple core pieces are fixed between each other in the axial direction by fixing portions. Therefore, the rotor core can form positioning portions with fewer pieces than the total number of stacked core pieces, thereby suppressing the effects of lamination misalignment, etc., reducing the dimensional tolerance of the positioning portions, and improving positioning accuracy.

[0040] Furthermore, according to the rotor of embodiment 2 configured as described above, the rotor core has multiple types of core pieces, one type of core piece has a through hole that forms the through hole, and the other type of core piece has a positioning hole that forms the positioning portion, so that the positioning portion can be easily formed in the through hole simply by adjusting the stacking order of the multiple types of core pieces.

[0041] Furthermore, according to the rotor of the second embodiment configured as described above, since the positioning portion has a circular shape, a circle can be easily processed with excellent precision compared to a polygonal shape, etc., and processing costs can be reduced. Also, in press processing, since the shape is circular, there are no sharp edges, which increases mold rigidity and improves mold life. Furthermore, because it is circular, the dimensional items that need to be managed during assembly can be minimized, simplifying assembly.

[0042] Embodiment 3. Figure 11 is a longitudinal cross-sectional view showing the configuration of a rotor core of a rotor according to embodiment 3. In the figure, parts that are the same as those in the above-described embodiments are given the same reference numerals, and descriptions thereof will be omitted. As shown in Figure 11, in embodiment 3, for example, by adjusting the stacking positions of the core laminations 201 and 202 shown in Figures 9 and 10 of embodiment 2, positioning portions 4 are formed in the through-hole 6 at both end positions and a central position in the axial direction Y of the rotor core 20.

[0043] In this way, by forming the positioning portions 4 only at positions corresponding to the upper end, center, and lower end of the length of the rotor core 20 in the axial direction Y, the effects of lamination misalignment and the like can be suppressed, and positioning can be performed more efficiently than by providing positioning portions all along the axial direction Y. Also, in terms of dimensional control of the rotor core 20, by forming the positioning portions 4 at positions on both end sides, the positioning portions 4 can be visually observed, making dimensional measurement possible and allowing the required precision of the rotor core 20 to be easily controlled.

[0044] In addition, Figure 11 shows an example in which one core piece 202 having a positioning hole 40 is installed at each end position and one at the center position of the rotor core 20 in the axial direction Y, and the rest are composed of core pieces 201 having through holes 60, but there is no limit to the number of core pieces that can be installed, and multiple core pieces 202 having positioning holes 40 may be installed consecutively or discontinuously.

[0045] The rotor of embodiment 3 configured as described above has the same effects as the above embodiments, and since the positioning portions are formed at positions on both end face sides of the rotor core in the axial direction, the positioning portions can be visually observed, making it easy to manage the required precision of the rotor core.

[0046] Furthermore, according to the rotor of embodiment 3 configured as described above, the positioning portion is formed at the axial center of the rotor core, and therefore positioning is performed at the center of the through hole, thereby improving positioning accuracy.

[0047] Embodiment 4. Figure 12 is a longitudinal cross-sectional view showing the configuration of a rotor core of a rotor according to embodiment 4. In the figure, parts that are the same as those in the above-described embodiments are given the same reference numerals, and descriptions thereof will be omitted. As shown in Figure 12, in embodiment 4, for example, by adjusting the stacking positions of the core laminations 201 and 202 shown in Figures 9 and 10 of embodiment 2, positioning portions 4 are formed in the through-hole 6 only at positions on both ends in the axial direction Y of the rotor core 20.

[0048] In this way, by installing the positioning portions 4 only at the upper and lower end positions of the axial length Y of the rotor core 20, the effects of lamination misalignment, etc. can be suppressed, positioning can be performed at the points where lamination of the rotor core 20 begins and ends, the positioning portions 4 can be visually observed, and the required precision of the rotor core 20 can be easily managed.

[0049] The rotor of embodiment 4 configured as described above has the same effects as the above embodiments, and even if the positioning portions are formed only at positions on both axial end face sides of the rotor core, positioning can be achieved with a small number of positioning points, and the positioning portions can be visually observed, making it possible to easily manage the required precision of the rotor core.

[0050] Fifth Embodiment Fig. 13 is a longitudinal cross-sectional view showing the configuration of a rotor core of a rotor according to a fifth embodiment. Fig. 14 is a longitudinal cross-sectional view showing a state in which a positioning pin has been inserted into the rotor core shown in Fig. 13. In the figure, parts that are the same as those in the above-mentioned embodiments are given the same reference numerals, and their description will be omitted. As shown in Fig. 13, in the fifth embodiment, for example, by adjusting the stacking positions of the core laminations 201 and 202 shown in Figs. 9 and 10 of the second embodiment, the positioning portions 4 are formed in the through holes 6 only at the center positions in the axial direction Y of the rotor core 20.

[0051] In this way, by providing the positioning portion 4 only at the central position of the length of the rotor core 20 in the axial direction Y, it is possible to position the rotor core 20 at an average position of all lamination misalignment, and it is possible to position the rotor core 20 with fewer positioning points in accordance with the required precision. Furthermore, by providing the positioning portion 4 only at the central position in the axial direction Y, it is possible to shorten the length of the positioning pin 50 in the axial direction Y, for example, as shown in Fig. 14, and it is possible to suppress deformation of the positioning pin 50 during assembly.

[0052] The rotor of embodiment 5 configured as described above has the same effects as the above embodiments, and since the positioning portion is formed only at the axial center of the rotor core, positioning can be performed with a small number of positioning points, and the rotor core can be positioned even if the axial length of the positioning pin is short.

[0053] Sixth Embodiment. Figures 15, 16, 18, and 19 are longitudinal cross-sectional views showing various examples of the configuration of the rotor core of a rotor according to a sixth embodiment. Figure 17 is a longitudinal cross-sectional view showing the rotor core shown in Figure 16 with a positioning pin inserted. In the figures, parts similar to those in the above-mentioned embodiments are given the same reference numerals and their description is omitted. In the third and fourth embodiments, examples were shown in which the positioning portions 4 were formed at both ends in the axial direction Y, but this is not limited to this. In the sixth embodiment, for example, by adjusting the stacking positions of the core laminations 201 and 202 shown in Figures 9 and 10 of the second embodiment, the positioning portions 4 are formed at one end face in the axial direction Y of the rotor core 20, as shown in the respective figures.

[0054] 15, the positioning portions 4 of the through holes 6 are formed only at the receiving surface side Y2 and at the center in the axial direction Y of the rotor core 20. Forming them in this manner suppresses the effects of lamination misalignment and the like compared to when the positioning portions 4 are formed at both ends in the axial direction Y, and allows the length of the positioning pins 50 to be shorter, as in the case shown in FIG.

[0055] 16, the positioning portion 4 of the through hole 6 is formed only at the position on the receiving surface side Y2 in the axial direction Y of the rotor core 20. By forming it in this manner, the influence of lamination misalignment can be minimized, and for example, as shown in FIG. 17, the length of the positioning pin 51 can be formed even shorter.

[0056] 18, the positioning portions 4 of the through holes 6 are formed only at the position on the press-fitting start side Y1 and at the center position in the axial direction Y of the rotor core 20. By forming them in this manner, the length of the positioning pin 5 becomes longer, but it is possible to position the area near the press-fitting start point, and it is possible to suppress galling when the rotating shaft 1 is press-fitted.

[0057] 19, the positioning portion 4 of the through hole 6 is formed only at a position on the press-fitting start side Y1 in the axial direction Y of the rotor core 20. By forming it in this manner, the effects of lamination misalignment and the like can be minimized, and galling when the rotating shaft 1 is press-fitted can also be suppressed.

[0058] The rotor of embodiment 6 configured as described above has the same effects as the above embodiments, and since the positioning portion is formed at a position on either end face side in the axial direction of the rotor core, positioning can be performed with fewer positioning points.

[0059] Embodiment 7. Figure 20 is a longitudinal cross-sectional view showing the configuration of a rotor core of a rotor according to embodiment 7. Figure 21 is a plan view showing the configuration of the rotor core shown in Figure 20. Figure 22 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 20. Figure 23 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 20, with Figure 23A showing the core pieces in a reference 0° state when rotated around the center of rotation shaft 1 as center point Q, and the other figures showing states rotated counterclockwise by a predetermined rotation angle from the state of Figure 23A. Figure 23B is a plan view showing states rotated 45°, Figure 23C is a plan view showing 90°, ... Figure 23D is a plan view showing 315°, and Figure 23E is a plan view showing states rotated one rotation and 360° (returning to 0°), in increments of 45°.

[0060] In the figures, parts that are the same as those in the above-described embodiments are assigned the same reference numerals, and descriptions thereof will be omitted. As shown in Figure 22, one type of core piece 203 includes both through holes 60 that form through holes 6 and positioning holes 40 that form positioning portions 4 within a single core piece 203. The through holes 60 are provided in a plurality of seven locations in the circumferential direction, and one positioning hole 40 is provided. The seven through holes 60 and one positioning hole 40 are formed at predetermined intervals of 45° in the circumferential direction.

[0061] 23A to 23E, the core pieces 203 shown in FIG. 22 are rotated by 45° around the center point Q, and are stacked in order from the receiving surface side Y2 in the axial direction Y, as shown in FIG. 20. As a result, positioning portions 4 are formed in all of the through holes 6 of the rotor core 20, as shown in FIG. 21. Here, an eight-pole rotor 2 is shown as an example. In the above example, the rotation angle is 45°, but this is not limited to this, and any rotation angle that is an integer multiple of 45° can be formed in the same way.

[0062] In this way, by rotating and laminating one type of core piece 203 having both the through holes 60 and the positioning holes 40 for each lamination, it becomes possible to provide the positioning portions 4 in a part of all of the through holes 6, simplifying the configuration of the die for pressing the core pieces 203 and thereby reducing the die costs. Here, an eight-pole rotor 2 is shown as an example, and the rotation angle of the rotation lamination is described as 45° (= 360° ÷ 8 poles), but by setting the rotation angle according to the number of poles, it is possible to apply the same to rotors 2 with any number of poles.

[0063] The rotor of embodiment 7 configured as described above has the same effects as the above embodiments, and in addition, the rotor core has a plurality of the through holes spaced at predetermined intervals in the circumferential direction, each core piece has a plurality of through holes that form the plurality of through holes and a positioning hole that forms the positioning portion, and the core pieces are formed by rotating and stacking the core pieces around the rotation axis, so that positioning portions can be easily formed in all of the through holes simply by sequentially rotating and stacking one type of core piece. Furthermore, because the rotor can be formed using only one type of core piece, only one type of mold is required to manufacture the core pieces, thereby reducing manufacturing costs.

[0064] Embodiment 8. Figure 24 is a longitudinal cross-sectional view showing the configuration of a rotor core of a rotor according to embodiment 8. Figure 25 is a plan view showing the configuration of the rotor core shown in Figure 24, as seen from the receiving surface side Y2 in the axial direction Y. Figure 26 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 24. Figure 27 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 24. Figure 27A shows the core pieces in a reference 0° state when rotated around the center of the rotation axis 1 as the center point Q. The other figures show states rotated counterclockwise by a predetermined rotation angle from the state shown in Figure 27A. Figure 27B shows a state after 90° rotation, Figure 27C shows a state after 180° rotation, Figure 27D shows a state after 270° rotation, and Figure 27E shows a state after one rotation and 360° rotation (back to 0°). Figure 28 is a longitudinal cross-sectional view showing a state after a positioning pin has been inserted into the rotor core shown in Figure 24. Figure 29 is a plan view showing a state after a positioning pin has been inserted into the rotor core shown in Figure 25.

[0065] In each of the above-described embodiments, a configuration has been shown in which the positioning portion 4 does not communicate with any location in plan view, but this is not limited to this, and in this eighth embodiment, a case will be described in which the positioning portion 4 has a notch 41 that connects to the press-fit hole 21. In the drawings, parts that are the same as those in each of the above-described embodiments are given the same reference numerals and their description will be omitted.

[0066] 26 , one type of core piece 204 includes both through holes 60 that form the through holes 6 and positioning holes 40 that form the positioning portions 4. Furthermore, the core piece 204 includes three through holes 60 in the circumferential direction and one positioning hole 40. The three through holes 60 and the one positioning hole 40 are formed at predetermined intervals of 90° in the circumferential direction. Furthermore, the positioning hole 40 includes a notch 41 that connects to the press-fit hole 21.

[0067] 27A to 27E, the core pieces 204 are rotated by 90° around the center point Q, and stacked in order from the receiving surface side Y2 in the axial direction Y, as shown in Fig. 24. Then, as shown in Fig. 25, positioning portions 4 are formed in all of the through holes 6 of the rotor core 20.

[0068] In this way, by rotating and stacking one type of core piece 204 having both a through hole 60 and a positioning hole 40 for each stack, it becomes possible to install a positioning portion 4 in a part of the through hole 6, thereby simplifying the mold configuration for press-processing the core piece 204 and thereby reducing mold costs.

[0069] 28 and 29, the rotor 2 can be manufactured by inserting the positioning pins 5 into the through holes 6 of the rotor core 20 in the same manner as in the above-described embodiments. When manufacturing the core pieces 204 of the rotor core 20 by pressing, if the size of the positioning holes 40 of the core pieces 204 is small and it is difficult to ensure the strength of the mold for punching out the positioning holes 40, it is possible to ensure the strength of the mold by forming the notches 41 in the positioning holes 40 and making them as large as possible, as shown in the eighth embodiment.

[0070] The rotor of embodiment 8 configured as described above has the same effects as the above embodiments, and since the positioning portion has a cutout portion that connects to the press-fit hole of the rotor core, the positioning portion can be easily formed in the through hole, and further, manufacturing costs can be reduced.

[0071] Embodiment 9. Figure 30 is a longitudinal cross-sectional view showing the configuration of a rotor core of a rotor according to embodiment 9. Figure 31 is a plan view showing the configuration of the rotor core shown in Figure 30, as seen from the receiving surface side Y2 in the axial direction Y. Figure 32 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 30. Figure 32 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 30. Figure 33A is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 30, and Figure 33B is a plan view showing the state after rotation of the core pieces by a predetermined rotation angle counterclockwise from the state of Figure 33A, with Figure 33B being a plan view showing the state after rotation of 90°, Figure 33C being a plan view showing the state after rotation of 180°, Figure 33D being a plan view showing the state after rotation of 270°, and Figure 33E being a plan view showing the state after rotation of one rotation and 360° (return to 0°).

[0072] Fig. 34 is a vertical cross-sectional view showing a state in which a positioning pin has been inserted into the rotor core shown in Fig. 30. Fig. 35 is a plan view showing a state in which a positioning pin has been inserted into the rotor core shown in Fig. 31.

[0073] In the above-described eighth embodiment, the positioning portion 4 has a notch 41 that connects to the press-fit hole 21, but in the present ninth embodiment, a case will be described in which the positioning portion 4 has a notch 42 that connects to the outer circumferential surface 22. In the drawings, parts that are the same as those in the above-described embodiments are given the same reference numerals and descriptions thereof will be omitted.

[0074] 32 , one type of core piece 205 includes both through holes 60 that form the through holes 6 and positioning holes 40 that form the positioning portions 4. Furthermore, the core piece 205 includes three through holes 60 in the circumferential direction and one positioning hole 40. The three through holes 60 and the one positioning hole 40 are formed at predetermined intervals of 90° in the circumferential direction. Furthermore, the positioning hole 40 includes a notch 42 that connects to the outer circumferential surface 22.

[0075] 33A to 33E, the core pieces 205 are rotated by 90° around the center point Q, and stacked in order from the receiving surface side Y2 in the axial direction Y, as shown in Fig. 30. Then, as shown in Fig. 31, positioning portions 4 are formed in all of the through holes 6 of the rotor core 20.

[0076] In this way, by rotating and stacking one type of core piece 205 having both a through hole 60 and a positioning hole 40 for each stack, it becomes possible to install a positioning portion 4 in a portion of every through hole 6, thereby simplifying the mold configuration for press-processing the core piece 205 and thereby reducing mold costs.

[0077] 34 and 35 , the rotor 2 can be manufactured by inserting the positioning pins 5 into the through holes 6 of the rotor core 20 in the same manner as in the above-described embodiments. When manufacturing the core pieces 205 of the rotor core 20 by pressing, if the size of the positioning holes 40 of the core pieces 205 is small and it is difficult to ensure the strength of the mold for punching out the positioning holes 40, it is possible to ensure the strength of the mold by forming the notches 42 in the positioning holes 40 and making them as large as possible, as shown in the ninth embodiment.

[0078] The rotor of embodiment 9 configured as described above has the same effects as the above embodiments, and since the positioning portion has a cutout portion that connects to the outer peripheral surface of the rotor core, the positioning portion can be easily formed in the through hole, and further, manufacturing costs can be reduced.

[0079] Embodiment 10. Figure 36 is a longitudinal cross-sectional view showing the configuration of a rotor core of a rotor according to embodiment 10. Figure 37 is a plan view showing the configuration of the rotor core shown in Figure 36. Figure 38 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 36. Figure 39 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 36. Figure 39A shows the state where the reference when rotating the core pieces around the center of the rotation shaft 1 as center point Q is 0°, and the other figures show states rotated counterclockwise by a predetermined rotation angle from the state of Figure 39A. Figure 39B is a plan view showing states rotated 90°, Figure 39C is a plan view showing states rotated 180°, Figure 39D is a plan view showing states rotated 270°, and Figure 39E is a plan view showing states rotated one rotation and 360° (back to 0°).

[0080] Fig. 40 is a vertical cross-sectional view showing a state in which a positioning pin has been inserted into the rotor core shown in Fig. 36. Fig. 41 is a plan view showing a state in which a positioning pin has been inserted into the rotor core shown in Fig. 37. Fig. 42 is a perspective view showing the configuration of the positioning pin shown in Fig. 40.

[0081] In the eighth embodiment, an example was shown in which only the positioning portion 4 has the notch portion 41 that connects to the press-fit hole 21, but in the tenth embodiment, a case will be described in which the through hole 6 also has a notch portion 61 that connects to the press-fit hole 21. In the drawings, parts that are the same as those in the above-mentioned embodiments are given the same reference numerals and descriptions thereof will be omitted.

[0082] 38 , one type of core piece 206 includes both through holes 60 that form through holes 6 and positioning holes 40 that form positioning portions 4. Furthermore, the core piece 206 includes three through holes 60 in the circumferential direction and one positioning hole 40. The three through holes 60 and the one positioning hole 40 are formed at predetermined intervals of 90° in the circumferential direction. Furthermore, the through holes 60 include cutout portions 61 that connect to the press-fit holes 21, and the positioning holes 40 include cutout portions 41 that connect to the press-fit holes 21.

[0083] 39A to 39E, the core pieces 206 are rotated by 90° around the center point Q, and are stacked in order from the receiving surface side Y2 in the axial direction Y, as shown in Fig. 32. Then, as shown in Fig. 33, positioning portions 4 are formed in all of the through holes 6 of the rotor core 20.

[0084] In this way, by rotating and stacking one type of core piece 206 having both a through hole 60 and a positioning hole 40 for each stack, it becomes possible to install a positioning portion 4 in a portion of every through hole 6, thereby simplifying the mold configuration for press-processing the core piece 206 and thereby reducing mold costs.

[0085] Furthermore, as shown in Figures 40 and 41, a positioning pin 52 is inserted into the through hole 6 of the rotor core 20. At this time, since the positioning hole 40 and the through hole 60 are connected to the press-fit hole 21 via the cutouts 41 and 61, a positioning pin 52 as shown in Figure 42 can be used. The cross-sectional area of ​​the positioning pin 52 perpendicular to the rotating shaft 1 is larger than that of the positioning pins 5, 50, and 51 in the above embodiments. This increases the rigidity of the positioning pin 52. Therefore, deformation of the positioning pin 52 during assembly can be suppressed. In other steps, the rotating shaft 1 is inserted as in the above embodiments, and the rotor 2 can be manufactured.

[0086] The rotor of embodiment 10 configured as described above achieves the same effects as the above embodiments, and the positioning portion has a cutout portion that connects to the press-fit hole of the rotor core, and the through hole has a cutout portion that connects to the press-fit hole of the rotor core, so that a positioning pin with a large cross-sectional area can be inserted into the through hole via the cutout portion.

[0087] Embodiment 11. Figure 43 is a longitudinal sectional view showing the configuration of a rotor core of a rotor according to embodiment 11. Figure 44 is a plan view seen from the receiving surface side Y2 in the axial direction Y, showing the configuration of the rotor core shown in Figure 43. Figures 45 and 46 are plan views showing the configuration of core pieces of the rotor core shown in Figure 43. Figure 47 is a longitudinal sectional view showing a state in which a positioning pin has been inserted into the rotor core shown in Figure 43.

[0088] In each of the above embodiments, an example in which one rotor core 20 is installed relative to the rotating shaft 1 has been shown, but the present invention is not limited to this, and a case will be described in which multiple rotor cores 20, 25 are installed in the axial direction Y relative to the rotating shaft 1, shifted circumferentially by a preset phase angle. In the drawings, parts that are the same as those in the above embodiments are given the same reference numerals, and description thereof will be omitted.

[0089] As shown in Figures 43 and 44, the rotor 2 has an eight-pole, two-stage skew structure and includes rotor cores 20, 25. The rotor core 20 installed on the receiving surface side Y2 in the axial direction Y is the rotor core 20 shown in Figure 7 of the second embodiment, and uses the core pieces 201 in Figure 9 and the core pieces 202 in Figure 10. This rotor core 20 and a rotor core 25 that is circumferentially shifted from the rotor core 20 by a certain phase angle (skew angle) θ are fixed to the rotating shaft 1.

[0090] The rotor core 25 has multiple types of core pieces 200, and one type of core piece 207 shown in FIG. 45 has a through hole 60 that forms the through hole 6. Another type of core piece 208 shown in FIG. 46 has a positioning hole 40 that forms the positioning portion 4. The through hole 60 has a diameter W1, and the positioning hole 40 has a diameter W2, which are the same relationships as in the above-described embodiments. The rotor core 25 is formed by stacking multiple core pieces 200 in the axial direction Y. The multiple core pieces 200 are fixed between each other in the axial direction Y as fixing portions by, for example, crimping.

[0091] The rotor core 25 is formed by alternately stacking these core pieces 207 and 208 in the axial direction Y, so that a through hole 6 having a positioning portion 4 is formed in every other core piece 200 in the axial direction Y, as shown in Figure 43.

[0092] 45 with the core piece 201 of FIG. 9, and the core piece 208 of FIG. 46 with the core piece 202 of FIG. 10, the through holes 60 and the positioning holes 40 are formed in the same positions on a plane perpendicular to the axial direction Y. Therefore, the through holes 6 equipped with the positioning portions 4 formed in the core pieces 201, 201, 207, 208 are formed to penetrate in the axial direction Y, as shown in FIG. 43. Therefore, the positioning pins 53 are inserted into the through holes 6, and horizontal movement is suppressed by the positioning portions 4, as in the above-described embodiments, as shown in FIG.

[0093] In addition, Figure 43 shows an example in which core pieces 208 having the positioning holes 40 and core pieces 207 having the through holes 60 are stacked alternately in the axial direction Y, but by adjusting the mold configuration and stacking program for press-processing the core pieces 200, the positioning portion 4 in the through holes 6 can be placed at any position in the axial direction Y.

[0094] In this way, when multiple rotor cores 20, 25 are stacked in the axial direction Y with a preset phase angle θ offset, the accuracy of the phase angle θ is important because it leads to variations in torque ripple in the rotating electrical machine 100. By implementing this embodiment, assembly with high positioning accuracy becomes possible.

[0095] Furthermore, in this embodiment, an eight-pole, two-stage skew structure is shown as an example, but the present invention is not limited to this, and there is no restriction on the number of poles or stages, and it is also applicable to, for example, a ten-pole, three-stage skew structure. As the number of stages in the stage skew structure increases, the dimensional tolerances of the rotor cores 20, 25 accumulate and assembly becomes more difficult, so the present invention, which can improve positioning accuracy, becomes even more effective.

[0096] According to the rotor of embodiment 11 configured as described above, it is possible to achieve the same effects as the above embodiments, and in addition, a plurality of rotor cores are arranged in the axial direction of the rotating shaft, each of the plurality of rotor cores is shifted by a predetermined phase angle and fixed to the rotating shaft, and the through holes of the plurality of rotor cores are formed so as to communicate in the axial direction while the rotor cores are skewed.Therefore, even when a plurality of rotor cores are arranged in the axial direction, the dimensional tolerance of the positioning portions of each rotor core can be reduced, and a stator for a rotating electric machine can be assembled with suppressed performance variation.

[0097] Embodiment 12. Figure 48 is a longitudinal cross-sectional view showing the configuration of a rotor core of a rotor according to embodiment 12. Figure 49 is a plan view showing the configuration of the rotor core shown in Figure 48, as seen from the receiving surface side Y2 in the axial direction Y. Figure 50 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 48. Figure 51 is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 48, Figure 51A is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 48, Figure 51A is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 48, Figure 51B is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 48, Figure 51C is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 48, Figure 51D is a plan view showing the configuration of the core pieces of the rotor core shown in Figure 48, Figure 51E ...

[0098] Fig. 52 is a vertical cross-sectional view showing a state in which a positioning pin has been inserted into the rotor core shown in Fig. 48. Fig. 53 is a plan view showing a state in which a positioning pin has been inserted into the rotor core shown in Fig. 49.

[0099] In the above-described ninth embodiment, the case where the positioning portion 4 has the notch portion 42 connected to the outer peripheral surface 22 has been described, but in the twelfth embodiment, a case where the through hole 6 additionally has a notch portion 62 connected to the outer peripheral surface 22 will be described. In the drawings, parts that are the same as those in the above-described embodiments are given the same reference numerals, and their description will be omitted.

[0100] 50 , one type of core piece 209 includes both through holes 60 that form through holes 6 and positioning holes 40 that form positioning portions 4. Furthermore, the core piece 209 includes three through holes 60 in the circumferential direction and one positioning hole 40. The three through holes 60 and the one positioning hole 40 are formed at predetermined intervals of 90° in the circumferential direction. Furthermore, the positioning holes 40 include cutout portions 42 that connect to the outer peripheral surface 22. The through holes 60 include cutout portions 62 that connect to the outer peripheral surface 22.

[0101] 51A to 51E, the core pieces 205 are rotated by 90° around the center point Q, and stacked in order from the receiving surface side Y2 in the axial direction Y, as shown in Fig. 48. Then, as shown in Fig. 49, positioning portions 4 are formed in all of the through holes 6 of the rotor core 20.

[0102] In this way, by rotating and stacking one type of core piece 209 having both a through hole 60 and a positioning hole 40 for each stack, it becomes possible to install a positioning portion 4 in a portion of every through hole 6, thereby simplifying the mold configuration for press-processing the core piece 209 and thereby reducing mold costs.

[0103] 52 and 53 , the rotor 2 can be manufactured by inserting the positioning pins 5 into the through holes 6 of the rotor core 20 in the same manner as in the above-described embodiments. Furthermore, if a high holding force is required between the rotating shaft 1 and the rotor core 20, it is necessary to ensure rigidity near the press-fit holes 21. In this case, by forming the notches 42 and 62 that connect the positioning portions 4 and the through holes 6 to the outer peripheral surface 22, a decrease in rigidity near the press-fit holes 21 can be avoided. Furthermore, by forming the notches 42 and 62 that connect the positioning portions 4 and the through holes 6 to the outer peripheral surface 22, the rigidity of the positioning pins 5 can be ensured.

[0104] The rotor of embodiment 12 configured as described above has the same effects as the above embodiments, and the positioning portion has a cutout portion connected to the outer peripheral surface of the rotor core, and the through hole has a cutout portion connected to the outer peripheral surface of the rotor core, so that a decrease in the rigidity of the press-fit hole can be avoided.

[0105] In addition, the installation locations of the positioning portion 4 and the through hole 6 installed within the rotor core 20 shown in each of the above embodiments are not limited to the cases shown in each figure, and if they are installed appropriately depending on the structure of the rotor, the same effects as those of the above embodiments can be achieved.

[0106] Embodiment 13. In the above-mentioned embodiment 1, examples of parts other than the rotor of the rotating electric machine are shown, but a more specific example will be described in embodiment 13. Fig. 54 is a vertical cross-sectional view showing the configuration of a rotating electric machine according to embodiment 13. Fig. 55 is a plan view showing the configuration of the stator of the rotating electric machine shown in Fig. 54.

[0107] In the drawings, parts that are the same as those in the above-described embodiments are given the same reference numerals, and their description will be omitted. Through holes 6 and positioning portions 4 are formed on the outer periphery of the stator 8. Then, in the process of assembling the motor case 10, positioning pins 53 are inserted into the through holes 6 in which the positioning portions 4 are formed.

[0108] In the method of manufacturing the stator of the rotating electric machine of the thirteenth embodiment configured as described above, the positioning pins 53 are inserted into the through holes 6 having the positioning portions 4 of the stator 8, and the stator is placed on the surface of a jig. With the positioning of the stator 8 thus determined, the motor case 10 is assembled from the insertion direction T. At this time, the motor case 10 is also positioned.

[0109] Generally, the stator 8 is configured with connection parts for connecting to an ECU (electronic control unit) equipped with control functions, and high positioning accuracy is required when assembling the motor case 10 and the stator 8 for connection to the ECU. Therefore, as shown in Figure 54, similar to the above-mentioned embodiments, through holes 6 and positioning parts 4 are formed in the stator 8, and positioning pins 53 are inserted and installed, thereby enabling high positioning accuracy even when there is lamination misalignment, etc.

[0110] The present application is not limited to such rotating electrical machines, and can be applied to parts that require positioning relative to manufacturing equipment. In this case, the part that requires positioning relative to the manufacturing equipment can be similarly positioned as long as it has a through hole 6 into which a positioning pin 5 installed in the manufacturing equipment can be inserted, and the through hole 6 has a positioning portion 4 in a part of the through direction (the same direction as the axial direction Y) that has a diameter W2 that is smaller than the diameter W1 of the other part of the through hole 6, as in the case described above.

[0111] Although various exemplary embodiments and examples are described in this application, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless modifications not illustrated are contemplated within the scope of the technology disclosed in this application. For example, this includes cases where at least one component is modified, added, or omitted, or where at least one component is extracted and combined with components of another embodiment.

[0112] REFERENCE SIGNS LIST 1 rotating shaft, 10 motor case, 100 rotating electric machine, 2 rotor, 20 rotor core, 200 core pieces, 201 core pieces, 202 core pieces, 203 core pieces, 204 core pieces, 205 core pieces, 206 core pieces, 207 core pieces, 208 core pieces, 209 core pieces, 21 press-fit hole, 22 outer peripheral surface, 25 rotor core, 3 magnet, 4 positioning portion, 40 positioning hole, 41 notch portion, 42 notch portion, 5 positioning pin, 50 positioning pin, 51 positioning pin, 52 positioning pin, 53 positioning pin, 6 through hole, 60 through hole, 61 notch portion, 62 notch portion, 8 stator, 9 coil, G gap, T insertion direction, W1 diameter, W2 diameter, W3 maximum diameter, Y Axial direction, Y1 press-fit start side, Y2 receiving surface side.

Claims

1. a rotor core on which a rotating shaft serving as the center of rotation of the rotating electric machine is installed; A rotor including a magnet installed in the rotor core, The rotor core has a press-fit hole into which the rotary shaft is inserted and fixed in an axial direction. a through hole formed between the press-fit hole and an outer peripheral surface of the rotor core, the through hole penetrating in an axial direction and at least one through hole formed in a circumferential direction; A rotor comprising a positioning portion in an axial portion of the through hole, the positioning portion having a diameter smaller than the diameter of the other portion of the through hole.

2. A plurality of the rotor cores are disposed in the axial direction of the rotating shaft, The rotor cores are fixed to the rotating shaft with a predetermined phase angle therebetween, 2. The rotor according to claim 1, wherein the through holes of the plurality of rotor cores are formed to communicate with each other in the axial direction while the rotor cores are skewed.

3. The rotor according to claim 1 or 2, wherein the positioning portions are formed at positions on both end face sides of the rotor core in the axial direction.

4. The rotor according to claim 1 or 2, wherein the positioning portion is formed at a central portion of the rotor core in the axial direction.

5. The rotor according to claim 1 or 2, wherein the positioning portion is formed at a position on either one end face side of the rotor core in the axial direction.

6. The rotor according to claim 1 or 2, wherein the positioning portion includes a notch portion that is connected to the press-fit hole or the outer circumferential surface of the rotor core.

7. the positioning portion includes a notch portion that is connected to the press-fit hole of the rotor core, The rotor according to claim 1 or 2, wherein the through hole includes a notch portion that is connected to the press-fit hole of the rotor core.

8. The positioning portion includes a notch portion connected to the outer circumferential surface of the rotor core, The rotor according to claim 1 or 2, wherein the through hole includes a notch portion that is connected to the outer circumferential surface of the rotor core.

9. The rotor core is formed by stacking a plurality of core pieces in the axial direction, 3. The rotor according to claim 1, wherein the plurality of core pieces are fixed to each other at fixed portions between each other in the axial direction.

10. The core pieces of the rotor core include a plurality of types, One type of the core piece has a through hole that forms the through hole, The rotor according to claim 9 , wherein the other type of core piece is provided with a positioning hole that forms the positioning portion.

11. the rotor core has a plurality of the through holes spaced at preset intervals in a circumferential direction, One of the core pieces has a plurality of through holes that form a plurality of the through holes and a positioning hole that forms the positioning portion, The rotor according to claim 9 , wherein the rotor core is formed by rotating and stacking the core pieces around the rotation axis.

12. The rotor according to claim 1 or 2, wherein the positioning portion has a circular shape.

13. A rotor according to claim 1 or 2; A rotating electric machine comprising: a stator having a plurality of windings and disposed opposite the outer periphery of the rotor with a predetermined air gap therebetween.

14. 14. The rotating electric machine according to claim 13, wherein the rotating electric machine is a motor for an electric power steering of an automobile.

15. The method for manufacturing a rotor according to claim 1 or 2, a positioning pin having a maximum diameter that is smaller than a diameter of the other portion of the through hole and that can be inserted into the positioning portion of the rotor core is inserted into the through hole having the positioning portion of the rotor core; A manufacturing method of a rotor, comprising: pressing and fitting the rotating shaft into the press-fit hole of the rotor core; and then removing the positioning pin from the rotor core.

16. For parts that are positioned relative to manufacturing equipment, the part has a through hole into which a positioning pin installed in the manufacturing device can be inserted, The through hole is a component having a positioning portion in a penetrating direction, the positioning portion having a diameter smaller than the diameter of the other portion of the through hole.

17. 17. The method of claim 16, further comprising the steps of: After inserting the positioning pin into the through hole having the positioning portion of the component, the positioning pin having a maximum diameter that is smaller than the diameter of the other portion of the through hole and can be inserted into the positioning portion, A manufacturing method for a part, comprising: performing a manufacturing process of the part using the manufacturing device; and thereafter removing the positioning pin from the part.