Method of manufacturing rotor of rotating electrical machine, rotor of rotating electrical machine, and rotating electrical machine

Abstract

In the present invention, in a step for manufacturing a rotor of a rotating electrical machine, a resin for bundling / fixing an iron core and a permanent magnet is prevented from leaking out from between layers of stacked steel plates constituting the iron core. To this end, this method of manufacturing a rotor of a rotating electrical machine comprises an injection step in which a resin (416) is injected into a through hole (417) in a state where a permanent magnet (415) has been inserted into the through hole (417), said through hole penetrating through a rotor core (405) constituted by a stack of a plurality of steel plates in a direction of the stack of the steel plates. In the injection step, among the plurality of steel plates constituting the rotor core (405), the variance in thickness of steel plates of a core material block (405a) that are stacked on an opening (417b) side opposite an injection port (417a) through which the resin (416) is injected into the through hole (417) is smaller than the variance in thickness of steel plates of a core material block (405a) other than the aforementioned core material block (405a), as well as of an end material block (405b).

Description

Method for manufacturing rotor for rotating electric machine, rotor for rotating electric machine, and rotating electric machine

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

[0002] For example, Patent Document 1 discloses a technique for manufacturing a rotor for a rotating electric machine, in which "a film-like adhesive 16 is applied to the surface of a strip-shaped electromagnetic steel sheet 12 supplied from a hoop material 11, and these are simultaneously punched and laminated into a predetermined shape to form an iron core 51. Permanent magnets 52 are then inserted into grooves 23 of the iron core 51, and the film-like adhesive 16 is then melted and spread by heating and pressurizing, filling the grooves 23 as well, thereby simultaneously binding the iron core 51 and bonding the iron core 51 to the permanent magnets 52." This rotor manufacturing method is said to prevent a decrease in adhesive strength due to poor adhesion and a decrease in magnetic performance due to air gaps when binding the laminated iron core with adhesive and bonding the iron core to the permanent magnets.

[0003] Japanese Patent Application Laid-Open No. 2000-152570

[0004] However, in the above-mentioned conventional technology, there was a problem in the manufacturing process of the rotor of the rotating electric machine that the resin used as an adhesive to bind and fix the iron core and permanent magnet leaked out from between the layers of the laminated steel plates that make up the iron core, requiring work to scrape off or wipe off the leaked resin.

[0005] The present invention has been made in consideration of the above circumstances, and aims to prevent resin used to bind and fix the iron core and permanent magnets from leaking between the layers of laminated steel plates that make up the iron core during the manufacturing process of the rotor of a rotating electric machine.

[0006] As one aspect for solving the above problem, there is provided a method for manufacturing a rotor for a rotating electric machine, the method comprising an injection step of injecting resin into through holes that penetrate an iron core of the rotor, which is formed by stacking a plurality of steel plates, with permanent magnets inserted into the through holes that pass through the iron core in the stacking direction of the plurality of steel plates, and wherein, in the injection step, the variation in thickness of a first group of steel plates that are stacked on the opening side of the through holes opposite the injection port through which the resin is injected is smaller than the variation in thickness of steel plate groups other than the first group of steel plates.

[0007] According to the present invention, in the manufacturing process of a rotor for a rotating electric machine, it is possible to prevent the resin used to bind and fix the iron core and permanent magnets from leaking out from between the layers of the laminated steel plates that make up the iron core. Problems, configurations, and effects other than those described above will become clear from the description of the following embodiments.

[0008] 1 is a configuration diagram of a vehicle equipped with a rotating electric machine according to embodiment 1. FIG. 2 is a cross-sectional view showing the configuration of the rotating electric machine according to embodiment 1. FIG. 3 is a cross-sectional view showing the configuration of a rotor of the rotating electric machine according to embodiment 1. FIG. 4 is an exploded perspective view showing the configuration of the rotor of the rotating electric machine according to embodiment 1. FIG. 5 is a side view showing the configuration of a rotor core of the rotor of the rotating electric machine according to embodiment 1. FIG. 6 is a schematic view showing cutting out laminated members from a steel plate in a manufacturing process of the rotating electric machine according to embodiment 1. FIG. 7 is a cross-sectional view showing a main part of the rotor core of the rotating electric machine according to embodiment 1. FIG. 8 is a cross-sectional view showing a main part of the rotor of a rotating electric machine according to a comparative example. FIG. 9 is a flowchart showing a formation process of a rotor core block of the rotating electric machine according to embodiment 1. FIG. 10 is a side view showing the configuration of a rotor core of the rotor of the rotating electric machine according to embodiment 2.

[0009] Hereinafter, embodiments of the present application will be described with reference to the drawings. Note that the following embodiments do not limit the present invention, and not all of the components and combinations thereof described in the embodiments are necessarily essential to the solution of the invention. The number of each component in the following embodiments may be singular or plural, unless otherwise specified.

[0010] In the following embodiments, the same reference numerals are used to designate the same features as those in the previous embodiments, and the description of the latter embodiments will be omitted, with the focus being on the differences. Furthermore, in the following embodiments, a combination of part or all of one embodiment with part or all of another embodiment is also included in the present application as long as there is no contradiction and there is consistency.

[0011] In the following description, identical or similar components will be denoted by the same reference numeral. When there are multiple identical or similar components, they may be denoted by the same reference numeral with different subscripts. When there is no need to distinguish between multiple components, the subscripts may be omitted.

[0012] In the following embodiments, an XYZ coordinate system is used for explanation, but the coordinates of each component merely indicate the relative positional relationship and do not limit the shape or size of each component. In the following embodiments, as an example, the Z-axis direction is the vertical direction, the positive Z-axis direction is the vertically upward direction, and the negative Z-axis direction is the vertically downward direction, but this is not limiting.

[0013] [First Embodiment] (Configuration of a vehicle 100 equipped with a rotating electric machine 200 according to a first embodiment) Fig. 1 is a configuration diagram of a vehicle 100 equipped with a rotating electric machine 200 according to a first embodiment. The vehicle 100 is, for example, a hybrid vehicle, but is not limited to this.

[0014] The vehicle 100 is equipped with an engine 120, a rotating electric machine 200, and a high-voltage battery 150. The battery 150 is formed of a secondary battery such as a lithium-ion battery or a nickel-metal hydride battery, and outputs high-voltage DC power of 250 to 600 volts or more. The battery 150 supplies DC power to the rotating electric machine 200 when driving force from the rotating electric machine 200 is required, and is supplied with DC power from the rotating electric machine 200 during regenerative running. DC power is exchanged between the battery 150 and the rotating electric machine 200 via a power conversion device 160.

[0015] The vehicle 100 is also equipped with a battery (not shown) that supplies low-voltage power (for example, 14-volt power). Rotational torque from the engine 120 and the rotating electric machine 200 is transmitted to the front wheels 110 via the transmission 130 and the differential gear 140.

[0016] (Configuration of rotating electric machine 200 according to embodiment 1) Fig. 2 is a cross-sectional view showing the configuration of rotating electric machine 200 according to embodiment 1. Fig. 2 shows the inside of rotating electric machine 200 by showing a part of rotating electric machine 200 in cross section.

[0017] 2, the rotating electric machine 200 has a stator 300 supported inside a housing 205. The stator 300 has a stator core 305 and a stator coil 510. The rotor 400 is rotatably supported on the inner periphery of the stator core 305 via an air gap 502.

[0018] Rotor 400 has rotor core 405 fixed to shaft 430, which is the rotation axis of rotor 400, permanent magnets 415, and non-magnetic end plates 420. Housing 205 has a pair of end brackets 210 provided with bearings 425, 426, and shaft 430 is rotatably supported by these bearings 425, 426. End plates 420 are fixed to shaft 430 by press fitting, shrink fitting, or the like.

[0019] The rotating electric machine 200 is a three-phase synchronous motor with built-in permanent magnets. The rotating electric machine 200 operates as an electric motor that rotates a rotor 400 when a three-phase AC current is supplied to a stator coil 510 wound around a stator core 305. When driven by the engine 120, the rotating electric machine 200 also operates as a generator and outputs three-phase AC generated power. In other words, the rotating electric machine 200 has both the function of an electric motor that generates rotational torque using electrical energy and the function of a generator that generates power using mechanical energy, and can selectively use either of these functions depending on the driving state of the vehicle.

[0020] Fig. 3 is a cross-sectional view (A-A cross-sectional view (Fig. 2)) of the stator 300 and the rotor 400 according to the first embodiment. Fig. 4 is an exploded perspective view (as viewed from the positive Z-axis direction) showing the configuration of the rotor 400 of the rotating electric machine 200 according to the first embodiment. Note that the housing 205 and the shaft 430 are omitted from Fig. 3.

[0021] The stator core 305 is formed by stacking multiple magnetic materials (e.g., multiple electromagnetic steel plates) in the axial direction, and is composed of a yoke portion and teeth portions (also called protrusions or salient poles). The yoke portion is composed of a cylindrical yoke core 306 (also called a core back) fitted to the inner periphery of the housing 205. The teeth portion is composed of multiple tooth cores 307 that protrude radially from the inner periphery of the yoke core 306 and are arranged circumferentially at predetermined intervals.

[0022] 3, not all teeth are labeled with reference numerals, but only some tooth cores 307 are labeled as representative. Between each pair of adjacent tooth cores 307, a plurality of slots 310 are formed that are continuous in the circumferential direction and on the rotor 400 side. Slot insulation (not shown) made of slot liners is provided within the slots 310, and windings of multiple phases such as U-phase, V-phase, and W-phase that constitute the stator 300 are installed. In this embodiment, the stator coil is wound using distributed winding.

[0023] On the other hand, the rotor core 405 is formed by stacking multiple magnetic materials, such as multiple electromagnetic steel sheets, in the Z-axis direction, and the electromagnetic steel sheets have permanent magnet insertion holes 410 into which permanent magnets are inserted. The permanent magnet insertion holes 410 are formed at equal intervals in the circumferential direction near the outer periphery of the rotor core 405, and a permanent magnet is embedded in each permanent magnet insertion hole. The width and thickness of the permanent magnet insertion holes 410 are formed to be larger than the width and thickness of the permanent magnets 415. As a result, a gap is formed between the surface of the permanent magnet 415 and the inner wall of the permanent magnet insertion hole 410, improving the ease of insertion of the permanent magnets 415 during assembly. The permanent magnets 415 act as field poles for the rotor 400.

[0024] Neodymium-based or samarium-based sintered magnets, ferrite magnets, neodymium-based bonded magnets, etc. can be used for the permanent magnet 415. The residual magnetic flux density of the permanent magnet 415 is approximately 0.4 to 1.3T.

[0025] 5 is a side view (side view parallel to the YZ plane) showing the configuration of the rotor core 405 of the rotor 400 of the rotating electric machine 200 according to embodiment 1. As shown in FIG. 5, the rotor core 405 is configured by stacking a plurality of annular core blocks 405a and offcut blocks 405b in the Z-axis direction. The core blocks 405a and offcut blocks 405b are rotationally stacked.

[0026] In this embodiment, the rotor core 405 is configured by stacking four core blocks 405a in the Z-axis direction and one waste block 405b in the positive Z-axis direction. Each of the core blocks 405a and waste block 405b has permanent magnets 415 inserted in the negative Z-axis direction as shown in Figure 4 and arranged at intervals in the Y-axis direction as shown by the dashed lines in Figure 5.

[0027] Furthermore, each of the core block 405a and the scrap block 405b is constructed by stacking laminated members in the positive direction of the Z axis, in which steel plates cut from coil material 500 (Figure 6) to a fixed length in the X axis direction are divided by slits at predetermined intervals in the Y axis direction.

[0028] 6 is a schematic diagram showing cutting out laminated members from steel plates in the manufacturing process of the rotating electric machine 200 according to the embodiment 1. Cutting out plate materials from the steel plates will be described with reference to FIG.

[0029] The coil material 500 is, for example, a steel sheet material obtained by winding up a sheet of electromagnetic steel sheet that has been rolled with the rolling direction in the positive direction of the X-axis. As shown in Figure 6, the coil material 500 is cut to a fixed length in the positive direction of the X-axis, which is the withdrawal direction, to form a steel sheet 501. Slits 501s are provided at predetermined intervals in the Y-axis direction to divide the steel sheet 501, forming a plurality of core materials 501a, scrap materials 501b, and waste materials 501z. The core materials 501a, scrap materials 501b, and waste materials 501z are each managed separately. Note that if the length of the steel sheet 501 in the Y-axis direction is an integer multiple of the predetermined interval, no waste materials 501z are generated.

[0030] The scrap material 501z includes both ends of the steel plate 501 in the direction perpendicular (Y-axis direction) to the rolling direction (X-axis direction), but is discarded because its length in the Y-axis direction does not meet the standard. By equally dividing the part of the steel plate 501 excluding the scrap material 501z, a core material 501a and scrap material 501b that will become the laminated members are formed.

[0031] The core material 501a satisfies the width standard in the Y-axis direction and has a uniform thickness in the Z-axis direction along the Y-axis, so it is used to form the core material block 405a. The scrap material 501b satisfies the width standard in the Y-axis direction but has a non-uniform thickness in the Z-axis direction along the Y-axis (the thickness in the Z-axis direction becomes thinner toward one side of the Y-axis), so it is used to form the scrap material block 405b.

[0032] Fig. 7 is a cross-sectional view showing a main part of rotor core 405 of rotating electric machine 200 according to embodiment 1. Fig. 7 is a cross-sectional view showing one end side in the negative Y-axis direction of cross section BB (Fig. 4).

[0033] As shown in Figure 7, the rotor core 405 is constructed by stacking four core blocks 405a in the positive direction of the Z axis, and then stacking one waste block 405b on top of the four core blocks 405a in the positive direction of the Z axis. Each core block 405a is constructed by stacking multiple core blocks 501a. Each waste block 405b is constructed by stacking waste blocks 501b with their thinner portions aligned.

[0034] As can be seen from Figure 7, because the thickness of core material 501a in the Z-axis direction is uniform across the Y-axis direction, the stacking spacing is dense on the negative Y-axis side of core material block 405a. On the other hand, because the thickness of scrap material 501b in the Z-axis direction is non-uniform across the Y-axis direction, the stacking spacing is sparse on the negative Y-axis side of scrap material block 405b. In other words, in rotor core 405 of this embodiment, scrap material block 405b, in which scrap material 501b is stacked, is positioned fifth from the negative Z-axis direction, and the stacking spacing at one end on the negative Y-axis side is sparse.

[0035] That is, among the multiple steel plates that make up rotor core 405, the thickness variation of the first group of steel plates stacked on the side of opening 417b opposite injection port 417a through which resin 416 is injected in through hole 417 is smaller than the thickness variation of the steel plate groups other than the first group of steel plates. The first group of steel plates is core block 405a at the bottom in the Z-axis direction in Figure 7. The steel plate groups other than the first group of steel plates are scrap block 405b at the top in the Z-axis direction in Figure 7, or the second and third core blocks 405a in the Z-axis direction and scrap block 405b at the top in the Z-axis direction.

[0036] 7 , the rotor core 405 has a permanent magnet 415 inserted into the through-hole 417, and resin 416, which serves as an adhesive, is injected into the through-holes that penetrate the steel plates or core blocks 405a and the scrap blocks 405b in the stacking direction. Here, the amount of resin 416 per unit volume between the steel plates of the first steel plate group is less than the amount of resin 416 per unit volume between the steel plates of the steel plate groups other than the first steel plate group. Conversely, the amount of resin 416 per unit volume between the steel plates of the steel plate groups other than the first steel plate group is greater than the amount of resin 416 per unit volume between the steel plates of the first steel plate group. This means that the amount of resin 416 in the scrap block 405b is greater by the amount that leaks from the through-hole 417 and extends between the layers of the scrap block 405b.

[0037] The through holes 417 are formed by holes that were previously drilled in the core 501 a and the waste material 501 b when the core block 405 a and the waste material block 405 b are formed. Alternatively, the through holes 417 may be formed by drilling after the core block 405 a and the waste material block 405 b are formed.

[0038] As shown by the arrows in Figure 7, the rotor core 405 has a permanent magnet 415 inserted into the through-hole 417 through the injection port 417a in the negative direction of the Z axis, and resin 416 is filled into the gaps between the permanent magnet 415 and the core block 405a and the scrap block 405b. The resin 416 is subjected to pressure in the negative direction of the Z axis by the filling pressure or its own weight, but it does not leak out from the sparse stacking gaps on the negative Y axis side of the scrap blocks 405b stacked on the injection port 417a side of the through-hole 417. It also does not leak out from the sparse stacking gaps on the negative Y axis side of the first steel plate group (scrap blocks 405b) stacked on the opening 417b side of the through-hole 417 opposite the injection port 417a.

[0039] 8 is a cross-sectional view showing a main part of a rotor of a rotating electric machine according to a comparative example, showing one end side of the rotating electric machine according to the comparative example taken along the line B-B in the negative Y-axis direction, similar to FIG.

[0040] 8, in the rotor core 405Z of the comparative example, the scrap material 501b is stacked first from the negative side of the Z axis. As shown by the arrow in Fig. 8, a permanent magnet 415 is inserted toward the negative side of the Z axis, and resin 416 is filled into the gaps between the permanent magnet 415 and the core block 405a and the scrap material block 405b. Then, due to the pressure exerted in the negative side of the Z axis by the filling pressure or its own weight, some of the resin 416a leaks out from the sparse lamination gap on the negative side of the Y axis of the scrap material block 405b.

[0041] (Process for forming the rotor core 405 of the rotating electric machine 200 according to the first embodiment) Fig. 9 is a flowchart showing the process for forming the rotor core 405 of the rotating electric machine 200 according to the first embodiment. The process for forming the rotor core 405 is performed by an assembly device, but may also be performed manually.

[0042] First, in step S11, the assembling device divides the steel plate obtained by cutting the coil material 500 to a fixed length by providing slits at predetermined intervals to form a core material 501a, a scrap material 501b, and a waste material 501z (division step). Next, in step S12, the assembling device discards the waste material 501z obtained in step S11, and manages the core material 501a and the scrap material 501b so that they can be separated.

[0043] Next, in step S13, the assembly device collects and stacks the scrap materials 501b to form the scrap material block 405b. Next, in step S14, the assembly device collects and stacks the core materials 501a to form the core material block 405a. The order of steps S13 and S14 may be reversed.

[0044] Next, in step S15, the assembly device determines whether the stacking position of the blocks (core block 405a, waste block 405b) of rotor core 405 is the topmost row (the most positive side in the Z-axis direction). If rotor core 405 is not in the topmost row (step S15 NO), the assembly device proceeds to step S16, and if it is in the topmost row (step S15 YES), the assembly device proceeds to step S17.

[0045] In step S16, the assembly device stacks core blocks 405a at the stacking positions of the blocks of rotor core 405 to construct rotor core 405. When step S16 is completed, the assembly device returns the process to step S15. On the other hand, in step S17, the assembly device stacks waste blocks 405b at the stacking positions of the blocks of rotor core 405 to construct rotor core 405. When step S17 is completed, the assembly device proceeds to step S18.

[0046] Next, in step S18, the assembly device inserts the permanent magnet 415 into the rotor core 405 at a predetermined position in the negative direction of the Z axis, and injects the resin 416 (injection step).

[0047] (Effects of the First Embodiment) When stacking sheet metal to form the core of a rotating electrical machine, conventionally, scrap metal is discarded, or even if scrap metal is used, scrap metal is used in the stacking without distinguishing between scrap metal and core metal. When scrap metal is stacked without being managed, if a scrap metal block made of scrap metal is placed in the bottom layer and resin is injected vertically, resin leaks out between the layers due to variations in the thickness of the scrap metal, resulting in processes of scraping off and wiping off the resin. Furthermore, the resin leaking out between the layers reduces the precision of the core shape, and it is necessary to scrape off the resin or adjust the rotor balance to adjust the rotational balance.

[0048] However, in this embodiment, when stacking scrap blocks and core blocks to form the core, by placing the scrap blocks in a position other than the bottom row (preferably the top row) in the vertical direction, the worst-case adverse effects of resin leakage can be avoided. Furthermore, the accuracy of the rotor shape can be maintained, reducing the labor required to balance the rotor. Furthermore, by managing the scrap and using it to form the core of the rotating electrical machine, waste materials can be reduced, easing the burden on the environment.

[0049] In this embodiment, the method includes an injection step of injecting resin into through holes that penetrate a rotor core formed by stacking a plurality of steel plates in the stacking direction of the plurality of steel plates, with permanent magnets inserted in the through holes. In the injection step, the thickness variation of a first group of steel plates that are stacked on the opening side of the through holes opposite the injection port for injecting the resin among the plurality of steel plates that make up the iron core is smaller than the thickness variation of steel plates other than the first group of steel plates.

[0050] Therefore, according to this embodiment, compared to when steel plate groups other than the first steel plate group are arranged on the opening side opposite the injection port of the through hole, it is possible to reduce leakage of resin between layers of steel plate groups other than the first steel plate group due to the injection pressure of the resin from the injection port or the weight of the resin.

[0051] This embodiment also includes a dividing step of dividing the steel plate into scrap material including both ends perpendicular to the rolling direction of the steel plate and scrap material and core material other than the scrap material, which are formed by dividing the steel plate excluding the scrap material. Furthermore, a block construction step is included in which the scrap materials are stacked in the stacking direction to form scrap blocks, and the core materials are stacked in the stacking direction to form core blocks. Furthermore, when stacking the scrap materials and core materials in the stacking direction to form an iron core, a core construction step is included in which at least the core materials blocks are stacked as a first steel plate group.

[0052] Therefore, according to this embodiment, by managing scrap materials to form scrap blocks and then stacking the scrap blocks and core blocks to form the rotor core, it is possible to reduce waste materials and alleviate the burden on the environment. Furthermore, by arranging the scrap blocks in a position other than the opening side of the through-hole opposite the injection port when forming the rotor core, it is possible to reduce waste materials while simultaneously achieving an efficient manufacturing process that does not require wiping off resin, maintaining the balance accuracy of the rotor, and maintaining the quality of the rotating electric machine.

[0053] In this embodiment, after the plurality of core blocks including the first steel plate group are stacked in the stacking direction, the scrap block is stacked in the stacking direction. That is, the scrap block is placed at a position on the injection port side of the through hole.

[0054] Therefore, according to this embodiment, it is possible to minimize leakage of resin from between the layers of the steel plates of the scrap block due to the injection pressure of the resin from the injection port or the weight of the resin itself.

[0055] In this embodiment, the scrap blocks and the core blocks are stacked while rotating in the circumferential direction around the rotation axis of the rotor.

[0056] Therefore, according to this embodiment, even when a rotor core is constructed by rotating and stacking scrap blocks and core blocks, it is possible to reduce the leakage of resin between the layers of steel plate groups other than the first steel plate group.

[0057] In this embodiment, the stacking direction of the scrap wood and the core wood, and the scrap wood blocks and the core wood blocks, is vertical.

[0058] Therefore, according to this embodiment, the resin leakage from between the layers of the steel plate group is strengthened due to the resin injection pressure from the injection port of the through hole of the rotor core and the weight of the resin, but even in this case, the leakage of resin from between the layers of steel plate groups other than the first steel plate group can be further reduced.

[0059] In addition, in this embodiment, the amount of resin injected per unit volume between the steel plates of the first steel plate group is less than the amount of resin injected per unit volume between the steel plates of steel plate groups other than the first steel plate group.

[0060] Therefore, according to this embodiment, the resin can flow out of the through holes and extend into the wide gaps between the steel plates of the scrap block, filling the gaps, without leaking outside the rotor core.

[0061] (Variation of Embodiment 1) In this embodiment, the scrap block 405b is arranged in the topmost tier of the rotor core 405, but this is not limiting and the scrap block 405b may be arranged in any tier other than the bottommost tier (the most negative side in the Z-axis direction) of the rotor core 405. By arranging the scrap block 405b in any tier other than the bottommost tier of the rotor core 405, the amount of resin 416a leaking from the sparse stacking gaps on the negative side of the Y-axis of the scrap block 405b can be further reduced compared to when the scrap block 405b is arranged in the bottommost tier of the rotor core 405.

[0062] In this embodiment, the scrap block 405b is composed only of the scrap 501b. However, this is not limited to this. The core block 405a may be composed only of the core 501a, while the scrap block 405b may be composed of a mixture of the core 501a and the scrap 501b. This method is also expected to be effective in reducing resin leakage between the layers of the steel plate groups other than the first steel plate group, without discarding the scrap 501b.

[0063] [Embodiment 2] Fig. 10 is a side view (side view parallel to the YZ plane) showing the configuration of a rotor core 405B of a rotor 400B of a rotating electric machine according to embodiment 2. As shown in Fig. 10, the rotor core 405B is configured by stacking a plurality of annular core blocks 405a and offcut blocks 405b in the Z-axis direction. The core blocks 405a and offcut blocks 405b are rotationally stacked.

[0064] In this embodiment, the core blocks 405a and the waste blocks 405b are stacked with respect to the core block 405a one level below (negative side of the Z axis) such that the ring of the rotor core 405B, which has the shaft 430 as its center of rotation, is rotated by a predetermined angle relative to the core block 405a. Therefore, the permanent magnets 415 inserted into each rotor core 405B are shifted in the Y-axis direction by a predetermined amount in the Z-axis direction, as shown by the dashed lines in Figure 10.

[0065] 11 is a flowchart showing the formation process of the rotor core 405B of the rotating electric machine according to the second embodiment. The formation process of the rotor core 405B of the rotating electric machine according to the second embodiment is the same as that of the first embodiment except that steps S16B and S17B are executed instead of step S16, and step S18B is executed instead of step S18.

[0066] In step S16B, the assembly device stacks the core block 405a at the stacking position of the block of the rotor core 405B. However, in step S16B, if there is a block one level lower than the stacking position of the block of the rotor core 405B, the assembly device stacks the core block 405a with a skew relative to the lower block as described above.

[0067] Next, in step S17B, the assembly device inserts the permanent magnet 415 into the core block 405a stacked in step S16B in the negative Z-axis direction at a predetermined position, and injects the resin 416 (injection step). After completing step S17B, the assembly device returns the process to step S15.

[0068] In step S18B, the assembly device inserts a permanent magnet 415 in the negative direction of the Z axis at a predetermined position of the scrap block 405b stacked in step S17, and injects resin 416 (injection step).

[0069] Second Embodiment In this embodiment, the offcut blocks and the core blocks are stacked with a skew in the circumferential direction around the rotation axis of the rotor.

[0070] Therefore, according to this embodiment, even when a rotor core is constructed by stacking scrap blocks and core blocks with a skew, it is possible to reduce the leakage of resin between the layers of steel plate groups other than the first steel plate group.

[0071] Although the embodiments of the present application have been described in detail above, the present disclosure is not limited to the above-described embodiments and can be modified in various ways without departing from the spirit of the present invention. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those including all of the described configurations. Furthermore, some of the configurations of the above-described embodiments can be added to, deleted from, or replaced with other configurations.

[0072] 200: rotating electric machine, 400, 400B: rotor, 405, 405B: rotor core, 405a: core block, 405b: scrap block, 415: permanent magnet, 416, 416a: resin, 417: through hole, 417a: injection port, 417b: opening, 430: shaft, 500: coil material, 501: steel plate, 501a: core material, 501b: scrap material, 501s: slit, 501z: waste material.

Claims

1. A manufacturing method for a rotor of a rotating electric machine, comprising an injection step of injecting resin into through holes that penetrate an iron core of the rotor, formed by stacking a plurality of steel plates, with permanent magnets inserted into the through holes that pass through the iron core in the stacking direction of the plurality of steel plates, wherein in the injection step, the thickness variation of a first group of steel plates that are stacked on the opening side of the through holes opposite the injection port through which the resin is injected is smaller than the thickness variation of steel plate groups other than the first group of steel plates.

2. A method for manufacturing a rotor for a rotating electric machine as described in claim 1, comprising: a dividing step of dividing the steel plate into scrap material including both ends perpendicular to the rolling direction of the steel plate, and end materials at both ends in the perpendicular direction formed by dividing the portion of the steel plate excluding the scrap material, and core material other than the scrap material; a block constructing step of stacking the end materials in the stacking direction to form end material blocks, and stacking the core materials in the stacking direction to form core material blocks; and an iron core constructing step of stacking at least the core material blocks as the first group of steel plates when stacking the end material blocks and the core material blocks in the stacking direction to form the iron core.

3. A method for manufacturing a rotor for a rotating electric machine as described in claim 2, characterized in that in the core construction process, a plurality of core blocks including the first group of steel plates are stacked in the stacking direction, and then the end material blocks are stacked in the same stacking direction.

4. A method for manufacturing a rotor for a rotating electric machine as described in claim 2, characterized in that in the core construction process, the end material blocks and the core blocks are rotated in a circumferential direction around the rotation axis of the rotor and stacked.

5. A method for manufacturing a rotor for a rotating electric machine as described in claim 2, characterized in that in the core construction process, the end material blocks and the core blocks are stacked with a circumferential skew around the rotation axis of the rotor relative to other end material blocks or other core blocks.

6. A method for manufacturing a rotor for a rotating electric machine according to claim 1, characterized in that the lamination direction is a vertical direction.

7. A method for manufacturing a rotor for a rotating electric machine as described in claim 6, characterized in that in the injection process, the amount of resin per unit volume between the steel plates of the first group of steel plates is less than the amount of resin per unit volume between the steel plates of steel plate groups other than the first group of steel plates.

8. A rotor for a rotating electric machine comprising: a rotor core constructed by stacking a plurality of steel plates; permanent magnets inserted into through holes provided in the rotor core; and resin extending into the through holes to fix the permanent magnets to the rotor core, wherein, of the plurality of steel plates constituting the rotor core, a first group of steel plates stacked on the opening side of the through holes opposite an injection port for injecting the resin has a smaller thickness variation than a group of steel plates other than the first group of steel plates, and the amount of resin per unit volume between the steel plates of the first group of steel plates is less than the amount of resin per unit volume between the steel plates of the steel plate groups other than the first group of steel plates.

9. A rotating electric machine comprising the rotor according to claim 8 and a stator.

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