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GB2625135A - A rotor and a method of manufacture of a rotor - Google Patents

A rotor and a method of manufacture of a rotor Download PDF

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Publication number
GB2625135A
GB2625135A GB2218452.7A GB202218452A GB2625135A GB 2625135 A GB2625135 A GB 2625135A GB 202218452 A GB202218452 A GB 202218452A GB 2625135 A GB2625135 A GB 2625135A
Authority
GB
United Kingdom
Prior art keywords
rotor
laminae
slot
magnet
slots
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
GB2218452.7A
Other versions
GB202218452D0 (en
Inventor
Bhartia Veral
Ananthanarayan Karthik
Negi Ayush
Prasad Praveen
Devara Prasad
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Jaguar Land Rover Ltd
Original Assignee
Jaguar Land Rover Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jaguar Land Rover Ltd filed Critical Jaguar Land Rover Ltd
Priority to GB2218452.7A priority Critical patent/GB2625135A/en
Publication of GB202218452D0 publication Critical patent/GB202218452D0/en
Publication of GB2625135A publication Critical patent/GB2625135A/en
Pending legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • H02K1/27Rotor cores with permanent magnets
    • H02K1/2706Inner rotors
    • H02K1/272Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • H02K1/28Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/021Magnetic cores

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

A rotor 10 comprising first rotor laminae 12, each of the first rotor laminae having a slot 16 of a first slot width 18; second rotor laminae 32, each of the second rotor laminae having a slot of a second slot width 38, the second slot width being smaller than the first slot width; the first rotor laminae and the second rotor laminae being stacked such that the slots of the first rotor laminae overlay the slots of the second rotor laminae, to form a rotor core comprising a stack of first rotor laminae and second rotor laminae with a rotor slot 56 therethrough; and a magnet 46 positioned in the rotor slot, wherein at least a portion of the second peripheral edge of one or more of the second rotor laminae slots does not overlay the first peripheral edge of the first rotor laminae slots and extends into the rotor slot whereby said portion of the second edge is deformed by the magnet on insertion of the magnet into the rotor slot to engage and retain the magnet in the rotor slot. A method of manufacture of a rotor and a vehicle comprising a rotor are also claimed.

Description

A ROTOR AND A METHOD OF MANUFACTURE OF A ROTOR
TECHNICAL FIELD
The present disclosure relates to a rotor and a method of manufacturing a rotor. Particularly, but not exclusively, the present disclosure relates to an electric machine rotor and a method of manufacturing an electric machine rotor for use in an interior permanent magnet electric machine that can be used as a motor or a generator.
Aspects of the invention relate to a rotor, to a method of manufacturing a rotor, to an electric machine, and to a vehicle.
BACKGROUND
It is known to use one or more electric machines in a vehicle. Such electric machines may operate as motors or as generators. Electric machines may operate as traction motors for propelling a vehicle such as an automobile, van, truck, motorcycle, boat, or aeroplane. Electric machines may be used in place of, or in addition to, an internal combustion engine.
Such electric machines comprise a stator and a rotor. The stator and rotor may form part of a permanent magnet synchronous motor arrangement. An air gap is maintained between the rotor and the stator. The stator is a stationary element of the electric machine which may comprise a plurality of slots within which electrical windings are located. The rotor is a rotating element of the electric machine allowing a transfer of electrical energy input into the motor to a mechanical output, such as the rotation of a driveshaft of the vehicle.
The rotor may comprise a plurality of laminations, generally of a ferromagnetic material, stacked to form a rotor core or rotor iron. Magnets are embedded in slots through each of the laminations of the rotor to form a plurality of rotor poles, the number and position of slots being dependent upon the required rotor topology. In a permanent magnet synchronous motor, the embedded magnets are permanent magnets and generate a magnetic flux. A rotor pole has a direct axis, or d-axis, aligned to the permanent magnet flux, and quadrature axes, or q-axes, denoted as a +q-axis and a -q-axis, arranged transverse to the direction of the rotor pole (i.e. transverse to the d-axis). The angular extent of each rotor pole, which is the included angle between the +q-axis and the -q-axis, is referred to as a pole step.
Current methods of manufacturing rotors require each magnet to be inserted into a rotor slot through the rotor and be retained in the rotor by the use of a wet process requiring the injection of an adhesive into the rotor slot whilst the magnet is located in position in the rotor slot. The adhesive retains the magnet and assists in conducting heat away from the magnet.
The vehicle may, for example, comprise a battery electric vehicle (BEV), a plug-in hybrid electric vehicle (PHEV) or a hybrid electric vehicle (HEV) where the electric machine is a traction motor for the vehicle. It is desirable to manufacture the rotor of the traction motor with a minimum number of manufacturing steps to minimise manufacturing complexity and cost, whilst maintaining motor performance and reliability.
It is an aim of the present invention to address one or more of the disadvantages associated with the prior art.
SUMMARY OF THE INVENTION
Aspects and embodiments of the invention provide a rotor, a method of manufacturing a rotor, an electric machine, and a vehicle as claimed in the appended claims.
According to an aspect of the present invention there is provided a rotor comprising: a plurality of first rotor laminae, each of the first rotor laminae having a slot therethrough, the slot of each of the first rotor laminae having a first slot width; a plurality of second rotor laminae, each of the second rotor laminae having a slot therethrough, the slot of each of the second rotor laminae having a second slot width, the second slot width being smaller than the first slot width; the plurality of first rotor laminae and the plurality of second rotor laminae being stacked such that the slots of the first rotor laminae overlay the slots of the second rotor laminae, to form a rotor core comprising a stack of first rotor laminae and second rotor laminae with a rotor slot therethrough, the rotor slot having a varying width through the rotor core; and a magnet positioned in the rotor slot, engaged with a first lengthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core.
An advantage of this aspect of the invention is that a direct mechanical engagement is provided between the magnet and the rotor laminae, reducing or eliminating the need for an additional wet process to retain magnets in the rotor slots, thus reducing the need for additional materials in the rotor construction and avoiding the need for specialised machinery for the injection of adhesive into the rotor slot. The invention also improves rotor reliability and thermal performance over rotors which have been manufactured using a wet process.
The magnet may be engaged with a second lengthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core. The engagement between the magnet and the first and second lengthwise edges of the slot of each of the second plurality of rotor laminae through the rotor core may be an interference engagement.
The magnet may be engaged with a first lengthwise edge of the slot of one or more of the first plurality of rotor laminae through the rotor core.
The magnet may be engaged with a second lengthwise edge of the slot of each of the first plurality of rotor laminae through the rotor core. The engagement between the magnet and the first and second lengthwise edges of the slot of the one or more of the first plurality of rotor laminae through the rotor core may be an interference engagement.
The magnet may be separated from a first lengthwise edge of the slot of each of the first plurality of rotor laminae through the rotor core.
The first lengthwise edge of the slot of each of the second plurality of rotor laminae may be deformed by the interference engagement between the magnet and the first and second lengthwise edges of the slot of each of the second plurality of rotor laminae through the rotor core. Each deformed first lengthwise edge of the slot of each of the second plurality of rotor laminae may exert a springback effect force on the magnet. This provides an advantage of retaining the magnet in-situ without the requirement of an adhesive to be applied between the magnet and the rotor laminae.
The slot of each of the first rotor laminae may have a first slot length orthogonal to the first slot width, and the slot of each of the second rotor laminae may have a second slot length orthogonal to the second slot width, where the second slot length may be smaller than the first slot length, and the magnet may be engaged with a first widthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core.
The magnet may be separated from a first widthwise edge of the slot of each of the first plurality of rotor laminae through the rotor core.
The rotor may be formed to comprise a plurality of rotor poles. Each rotor pole may comprise one or more slot therethrough in which a magnet may be positioned.
The second rotor laminae may be evenly distributed through the stack of first rotor laminae and second rotor laminae. This provides an advantage of ensuring that the rotor is balanced.
The second rotor laminae may comprise one in every n laminae of the stack of first rotor laminae and second rotor laminae. The value of n may be a value between two and ten.
According to an aspect of the present invention there is provided a method of manufacturing a rotor, the rotor having a rotational axis, the method comprising: stacking a plurality of first rotor laminae and a plurality of second rotor laminae to form a stack of first rotor laminae and second rotor laminae, each of the first rotor laminae having a slot therethrough, the slot of each of the first rotor laminae having a first slot width, and each of the second rotor laminae having a slot therethrough, the slot of each of the second rotor laminae having a second slot width, the second slot width being smaller than the first slot width, wherein the slots of the first rotor laminae overlay the slots of the second rotor laminae, to form a rotor core with a rotor slot therethrough, the rotor slot having a varying width through the rotor core; and inserting a magnet into the rotor slot to engage with a first lengthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core.
An advantage of this invention is that wet processes for retaining magnets in rotor slots can be avoided, thus reducing the need for additional materials in the rotor construction and avoiding the need for specialised machinery for the injection of adhesive into the rotor slot.
The invention also improves rotor reliability and thermal performance over rotors manufactured using a wet process.
The inserted magnet may engage with a second lengthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core. The engagement between the magnet and the first and second lengthwise edges of the slot of each of the second plurality of rotor laminae through the rotor core may be an interference engagement.
The insertion of the magnet into the rotor slot may cause engagement with a first lengthwise edge of the slot of one or more of the first plurality of rotor laminae through the rotor core.
The inserted magnet may engage with a second lengthwise edge of the slot of each of the first plurality of rotor laminae through the rotor core. The engagement between the magnet and the first and second lengthwise edges of the slot of the one or more of the first plurality of rotor laminae through the rotor core may be an interference engagement.
The magnet may be separated from a first lengthwise edge of the slot of each of the first plurality of rotor laminae through the rotor core.
The interference engagement between the magnet and the first lengthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core may cause deformation of the first lengthwise edge of the slot of each of the second plurality of rotor laminae. Each deformed first lengthwise edge of the slot of each of the second plurality of rotor laminae may exert a springback effect force on the magnet.
An advantage of this feature is that the springback effect force ensures that the magnet is well constrained against in-plane and axial movement of the magnet in the slot, as well as to ensure direct metal to metal contact for high conduction of heat away from the magnet.
The slot of each of the first rotor laminae may have a first slot length orthogonal to the first slot width, and the slot of each of the second rotor laminae may have a second slot length orthogonal to the second slot width, where the second slot length may be smaller than the first slot length, and insertion of the magnet into the rotor slot may engage the magnet with a first widthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core.
The magnet may be separated from a first widthwise edge of the slot of each of the first plurality of rotor laminae through the rotor core.
The rotor may be formed to comprise a plurality of rotor poles. Each rotor pole may comprise one or more rotor slot therethrough for the insertion of a magnet.
The second rotor laminae may be evenly distributed through the stack of first rotor laminae and second rotor laminae.
The second rotor laminae may comprise one in every n laminae of the stack of first rotor laminae and second rotor laminae. The value of n may be a value between two and ten.
According to an aspect of the present invention there is provided electric machine comprising a rotor according to any preceding aspect and a stator.
According to an aspect of the present invention there is provided a vehicle comprising an electric machine according to any preceding aspect.
According to a still further aspect of the present invention there is provided a method of manufacturing a rotor, the rotor having a rotational axis, the method comprising stacking a plurality of first rotor laminae to form a stack of first rotor laminae and second rotor laminae, each of the first rotor laminae having a slot therethrough, the slot of each of the first rotor laminae having a first peripheral edge and a plurality of second rotor laminae, each of the second rotor laminae having a slot therethrough, the slot of each of the second rotor laminae having a second peripheral edge the plurality of first rotor laminae and the plurality of second rotor laminae being stacked such that the slots of the first rotor laminae overlay the slots of the second rotor laminae, to form a rotor core with a rotor slot therethrough defined by the overlain slots of the first and second rotor laminae; and inserting a magnet positioned in the rotor slot, wherein at least a portion of the second peripheral edge of one or more of the second rotor laminae slots does not overlay the first peripheral edge of the first rotor laminae slots and extends into the rotor slot whereby said portion of the second edge is deformed by the magnet on insertion of the magnet into the rotor slot to engage and retain the magnet in the rotor slot.
Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.
BRIEF DESCRIPTION OF THE DRAWINGS
One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 illustrates a rotor according to an embodiment of the invention; Figure 2 illustrates a first rotor lamina of the rotor of Figure 1; Figure 3 illustrates a second rotor lamina of the rotor of Figure 1; Figure 4 illustrates the first rotor lamina of Figure 2 overlaying the second rotor lamina of Figure 3 in a rotor according to an embodiment of the invention; Figure 5 illustrates an arrangement of a rotor according to an embodiment of the invention; Figures 6a and 6b illustrate stages in a method of manufacturing a rotor according to an embodiment of the invention; Figure 7 illustrates an electric machine according to an embodiment of the invention; and Figure 8 illustrates a vehicle according to an embodiment of the invention.
DETAILED DESCRIPTION
Examples of the present disclosure relate to a rotor. In particular, examples of the present invention relate to an eight pole rotor with a pole step of forty five mechanical degrees, though it will be understood that a different number of poles, such as four or six, may be provided. Non-limiting examples will now be described with reference to accompanying Figures 1 to 8, where the figures illustrate a rotor 10, an electric machine 100, and a vehicle 200.
The rotor 10 is intended for use in an electric machine 100, as illustrated in Figure 7, where the electric machine 100 comprises the rotor 10 and a stator 90. The stator 90 comprises a plurality of slots extending radially inwardly to support electrical windings (not shown in the figures). For example, the electric machine 100 may comprise forty eight electrical winding slots in the stator 90 and eight rotor poles in the rotor 10. The electric machine 100 may provide the function of a motor and/or generator for operation in a vehicle 200. For example, the electric machine 100 may be a traction motor for an electric vehicle 200.
Figure 8 illustrates a vehicle 200 having a first electric machine 100-1 for driving one or more front wheels of the vehicle 200 and a second electric machine 100-2 for driving one or more rear wheels of the vehicle 200. In other embodiments the vehicle 200 may comprise only a single electric machine 100, arranged or configured to drive one of one or more front wheels of the vehicle 200 or one or more rear wheels of the vehicle 200. At a vehicle axle the electric machine 100 may be arranged to drive both wheels, either directly or through other transmission components. Other arrangements may have one electric machine 100 arranged or configured to drive each wheel of the vehicle 200.
With reference to Figure 1, there is shown a side view of a rotor 10, the rotor comprising a plurality of first rotor laminae 12 and a plurality of second rotor laminae 32 arranged in a stack of rotor laminae to form a rotor core 50. The rotor 10 may be comprised of a plurality of first rotor laminae 12 and a plurality of second rotor laminae 32 only, thereby reducing the need for further different laminae to be provided in the manufacture of the rotor 10.
An axial view of the rotor 10 is illustrated in Figure 4. The rotor 10 is formed to comprise a plurality of rotor poles, which in this example comprises eight poles. Each rotor pole comprising one or more rotor slot, or aperture, 56 therethrough in which a magnet 46 is positioned. The rotor 10 may form part of an electric machine 100, as illustrated in Figure 7, which may be used, for example, as a traction motor for a vehicle 200, as illustrated in Figure 8. The rotor 10 has a rotational axis 70 about which the rotor 10 is arranged or configured to rotate.
Figures 2 and 3 show examples of first 12 and second 32 laminae in plan view, in the axial direction of axis 70. With reference to Figure 2, each of the first rotor laminae 12 has a slot 16 therethrough, the slot 16 of each of the first rotor laminae 12 having a first slot width 18 in a widthwise direction, radial with respect to the rotor axis 70. With reference to Figure 3, each of the second rotor laminae 32 has a slot 36 therethrough. The slot 36 of each of the second rotor laminae 32 has a second slot width 38 in the widthwise direction, also radial with respect to the axis 70. The second slot width 38 is smaller than the first slot width 18. The arrangement and function of the first rotor laminae 12 and second rotor laminae 32 in the rotor 10 is described in more detail below with respect to Figure 4.
In Figure 2, which illustrates a first rotor lamina 12, the poles are illustrated as segments 14- 1, 14-2, 14-3, 14-4, 14-5, 14-6, 14-7, 14-8 of the first rotor lamina 12, each segment being identical to each other segment. Each of the segments 14-1, 14-2, 14-3, 14-4, 14-5, 14-6, 147, 14-8 of the first rotor lamina 12 of rotor 10 are bounded by a first quadrature axis, or +q axis, 74 and a second quadrature axis, or -q axis, 76. For simplicity, these axes are only shown for a first segment 14-1. For the first segment 14-1, the +q-axis 74 and the -q-axis 76 define the lateral boundaries of the first segment 14-1. Each of the segments 14-1, 14-2, 143, 14-4, 14-5, 14-6, 14-7, 14-8 comprises a respective identical slot 16 therethrough, though in some embodiments the slots 16 may be of different forms depending on lamination and magnet topology. Additionally it will be understood that each segment 14-1, 14-2, 14-3, 14-4, 14-5, 14-6, 14-7, 14-8, may comprise multiple slots 16 each of which may vary in form and orientation depending on lamination and magnet topology.
In some embodiments, the slot 16 within which the first permanent magnet arrangement 46 is positioned, or is to be positioned during manufacture of the rotor 10, may be offset from the d-axis and/or may be oriented at an angle to the d-axis. In some embodiments, each of the segments 14-1, 14-2, 14-3, 14-4, 14-5, 14-6, 14-7, 14-8 may comprise more than one slot 16 within which a respective permanent magnet arrangement 46 may be positioned or retained.
In some embodiments multiple slots 16 may be provided symmetrically about the d-axis, and in some of those embodiments at least some of the slots 16 may be oriented at an angle to the d-axis, for example to form a U or V shaped arrangement of slots 16 about the d-axis. In some embodiments there may be multiple layers of slots 16, that is, slots 16 which are radially separated from other slots 16 within each of the segments 14-1, 14-2, 14-3, 14-4, 14-5, 14-6, 14-7, 14-8. For simplicity, the arrangement illustrated and described in the following embodiments provides a single slot 16 centred on the d-axis and orthogonal thereto.
In particular, in the arrangement illustrated in Figure 2, first segment 14-1 comprises a slot 16 within which a first permanent magnet arrangement 46 may be positioned or retained, and disposed symmetrically about, the slot 16 having a first slot width 18. The first permanent magnet arrangement 46 may be substantially orthogonal to, a direct axis, or d-axis, 72 of the segment 14-1, as illustrated in Figure 4 and described further below, though it will be understood that in other embodiments the slot 16 may be oriented differently to that shown in Figure 2, and so the first permanent magnet arrangement 46 may be oriented differently to that shown in Figure 4, and therefore not necessarily be orthogonal to the d-axis 72. It will be understood that the width 18 is the shortest side of the slot 16 and the length 19 is the longest side of the slot 16, orthogonal to the shortest side of the slot 16.
The slot 16 within which the first permanent magnet arrangement 46 is positioned, or is to be positioned during manufacture of the rotor 10, may be symmetrically disposed about the d-axis 72. As illustrated in Figure 2 for the slot 16 in the first segment 14-1, the slot 16 has a first slot width 18 along the d-axis 72 orthogonal to the rotational axis 70 of the rotor 10, between a first lengthwise edge 20 of the slot 16 of the first rotor lamina 12 and a second lengthwise edge 22 of the slot 16 of the first rotor lamina 12. The first lengthwise edge 20 of the slot 16 of the first rotor lamina 12 may be a radially inner edge of the slot 16 of the first rotor lamina 12 and the second lengthwise edge 22 of the slot 16 of the first rotor lamina 12 may be a radially outer edge of the slot 16 of the first rotor lamina 12. Each of the segments of the first rotor lamina 12 comprises a slot 16 within which a permanent magnet arrangement 46 may be positioned and disposed symmetrically within. Of course, in arrangements where the slot 16 is not oriented orthogonal to the d-axis, the first lengthwise edge 20 may not necessarily be a radially inner edge of the slot 16 and the second lengthwise edge 22 of the slot 16 may not necessarily be a radially outer edge of the slot 16, for example where the slot 16 is oriented parallel to the d-axis.
In Figure 3, which illustrates a second rotor lamina 32, different to the first rotor lamina 12, the poles are illustrated as segments 34-1, 34-2, 34-3, 344, 34-5, 34-6, 34-7, 34-8, of the second rotor lamina 32, each segment being identical to each other segment. Each of the segments 34-1,34-2, 34-3, 34-4, 34-5, 34-6, 34-7, 34-8 of second rotor lamina 32 of rotor 10 are bounded by a first quadrature axis, or +q axis, 74 and a second quadrature axis, or -q axis, 76. For simplicity, these axes are only shown for a first segment 34-1. For the first segment 34-1, the +q-axis 74 and the -q-axis 76 define the lateral boundaries of the first segment 34-1. Each of the segments 34-1, 34-2, 34-3, 34-4, 34-5, 34-6, 34-7, 34-8 comprising a respective identical slot 36 therethrough, though in some embodiments the slots 36 may be of different forms depending on lamination and magnet topology. Additionally it will be understood that each segment 34-1, 34-2, 34-3, 34-4, 34-5, 34-6, 34-7, 34-8, may comprise multiple slots 36 each of which may vary in form and orientation depending on lamination and magnet topology.
In particular, in the arrangement illustrated in Figure 3, first segment 34-1 comprises a slot 36 within which the first permanent magnet arrangement 46 may be positioned or retained, and disposed symmetrically about. The first permanent magnet arrangement 46 may be substantially orthogonal to, a direct axis, or d-axis, 72 of the segment 34-1, as illustrated in Figure 4 and described further below. The slot 36 within which the first permanent magnet arrangement 46 is positioned may be symmetrically disposed about the d-axis 72. As illustrated in Figure 3 for the slot 36 in the first segment 34-1, the slot 36 has a first slot width 38 along the d-axis 72 orthogonal to the rotational axis 70 of the rotor 10, between a first lengthwise edge 40 (which can also be referred to as the second peripheral edge 40) of the slot 36 of the second rotor lamina 32 and a second lengthwise edge 42 of the slot 36 of the second rotor lamina 32. The first lengthwise edge 40 of the slot 36 of the second rotor lamina 32 may be a radially inner edge of the slot 36 of the second rotor lamina 32 and the second lengthwise edge 42 of the slot 36 of the second rotor lamina 32 may be a radially outer edge of the slot 36 of the second rotor lamina 32. Each of the segments of the second rotor lamina 32 comprises a slot 36 within which a permanent magnet arrangement 46 may be positioned or retained, and disposed symmetrically within. Of course, in arrangements where the slot 36 is not oriented orthogonal to the d-axis, the first lengthwise edge 40 may not necessarily be a radially inner edge of the slot 36 and the second lengthwise edge 42 of the slot 36 may not necessarily be a radially outer edge of the slot 36, for example where the slot 36 is oriented parallel to the d-axis.
It will be understood that the d-axis 72, +q axis 74 and -q axis 76 are radial axes, extending radially outwards from the rotational axis 70 of the rotor in the plane of the laminae, shared between the first rotor laminae 12 of the rotor 10 and the second rotor laminae 32 of the rotor 10.
Figure 4 illustrates overlaying of a first rotor laminae 12 on a second rotor laminae 32 to form a rotor 10. Whilst only the uppermost two laminae are observed in Figure 4, it will be understood that there will be a plurality of first rotor laminae 12 and a plurality of second rotor laminae 32 that form the rotor 10, as illustrated in the side view of Figure 1. The plurality of first rotor laminae 12 and the plurality of second rotor laminae 32 are stacked such that the slots 16 of the first rotor laminae 12 overlay the slots 36 of the second rotor laminae 32, to form a rotor core 50 comprising a stack of first rotor laminae 12 and second rotor laminae 32 with a magnet slot, or rotor slot, 56 therethrough, the rotor slot 56 having a varying width through the rotor core 50.
It will be understood that the segments 14-1, 14-2, 14-3, 14-4, first rotor laminae 12 overlay respective segments 34-1, 34-2, 14-5, 14-6, 14-7, 14-8 of the 34-3, 34-4, 34-5, 34-6, 34-7, 34-8, of the second rotor laminae 32, in the stack of rotor laminae forming the rotor core 50, that is, in the rotor 10 the first segments 14-1, 14-2, 14-3, 14-4, 14-5, 14-6, 14-7, 14-8 of the first rotor laminae 12 overlay the first segments 34-1, 34-2, 34-3, 34-4, 34-5, 34-6, 34-7, 34-8 of the second rotor laminae 32, along an axis parallel to the rotational axis 70 of the rotor 10.
A first permanent magnet arrangement which may be in the form of a single magnet 46, or segmented magnets 46, is positioned in the rotor slot 56. The magnet 46 is engaged with a first lengthwise edge 40 of the slot 36 of each of the second plurality of rotor laminae 32 through the rotor core 50.
In order to retain the magnet 46 in-situ in the rotor slot 56, the magnet 46 is engaged with a second lengthwise edge 42 of the slot 36 of each of the second plurality of rotor laminae 32 through the rotor core 50, wherein the engagement between the magnet 46 and the first and second lengthwise edges 40, 42 of the slot 36 of each of the second plurality of rotor laminae 32 through the rotor core 50 is an interference engagement. The function of the interference engagement is to ensure that the magnet 46 is constrained against planar and axial movement in the slot 36. The interference engagement also ensures direct contact between the magnet 46 and the second plurality of rotor laminae 32 through the rotor core 50 for conduction of heat away from the magnet 46.
The second lengthwise edge 22 of the slot 16 of the first rotor laminae 12 and the second lengthwise edge 42 of the slot 36 of the second rotor laminae 32 may be aligned along the rotor slot 56, in other words aligned along an axis parallel to the rotational axis 70 of the rotor 10. In this arrangement, the stack of first rotor laminae 12 and second rotor laminae 32 provide a rotor slot 56 where one lengthwise wall of the rotor slot 56 is planar. A magnet 46 inserted into such a rotor slot 56 will have an engagement with both the second lengthwise edge 22 of the slot 16 of the first rotor laminae 12 and the second lengthwise edge 42 of the slot 36 of the second rotor laminae 32 through the rotor core.
An advantage of this aspect of retaining the magnet 46 is that a direct mechanical engagement is provided between the magnet 46 and the rotor laminae 12, 32, reducing or eliminating the need for an additional wet process to retain magnets 46 in the rotor slots 56, thus reducing the need for additional materials in the rotor construction and avoiding the need for specialised machinery for the injection of adhesive into the rotor slot 56. This improves rotor reliability and thermal performance over rotors which have been manufactured using a wet process.
An embodiment of a rotor 10, is partly illustrated in Figure 5, which shows a single rotor slot 56. Along the rotor slot 56, which runs parallel to the rotational axis 70 of the rotor 10, the magnet 46 may also engage with a first lengthwise edge 20 of the slot 16 of one or more of the first plurality of rotor laminae 12 through the rotor core 50. Therefore, the magnet 46 may be engaged with the first lengthwise edge 20 and the second lengthwise edge 22 of the slot 16 of one or more of the first plurality of rotor laminae 12 through the rotor core 50. The engagement between the magnet 46 and the first and second lengthwise edges 20, 22 of the slot 16 of the one or more of the first plurality of rotor laminae 12 through the rotor core 50 may be an interference engagement. In such an embodiment, the predominant laminate deformation is planar, that is, in the plane of the rotor laminae 12, 32, such that it is this planar deformation of the rotor lamina 12, 32 that causes a subsequent load to be created to help retain the magnet in situ.
Such an engagement is dependent on the dimensional tolerance of the magnet 46 to be inserted into the rotor slot 56. The engagement may also be dependent on the dimensional tolerance of the slots 16 of the first plurality of rotor laminae 12. The engagement may also be dependent on the dimensional tolerance of the slots 36 of the second plurality of rotor laminae 32. A magnet width tolerance range 48, first slot width tolerance range 24 and second slot width tolerance range 44 are illustrated as separate box sections in Figure 5 indicating potential overlap of those components. For example, the magnet may be 2.5 mm wide, with a tolerance of +/-0.1 mm, such that the magnet width tolerance range 48 in the plane of the rotor laminae 12, 32, may be 0.2 mm.
In some embodiments, when the width of the magnet 46 is greater than the first slot width 18 of the slot 16 of the one or more of the first plurality of rotor laminae 12, then the magnet has an interference engagement with the first lengthwise edge 20 of the slot 16 of the one or more of the first plurality of rotor laminae 12. The number of laminae of the first plurality of rotor laminae 12 which will be in an interference engagement may depend upon the loads generated during the interference fit, the interference magnitude, and thermal requirements.
The laminae of the first plurality of rotor laminae 12 that are not in an interference engagement with the magnet 46 may be in a clearance fit, that is, not engaged with the magnet 46, or may be in a transition fit, that is, the slot 16 has the same or substantially the same width as the width of the magnet 46.
By only having certain laminae of the first plurality of rotor laminae 12 in an interference engagement, insertion stresses on the magnet 46 can be reduced, and surface damage to the magnet 46 can be reduced compared to having all of the first plurality of rotor laminae 12 in an interference engagement.
An embodiment of a rotor 10 is partly illustrated in Figure 6b, which shows a single rotor slot 56. The magnet is separated from a first lengthwise edge 20 of the slot 16 of each of the first plurality of rotor laminae 12 through the rotor core 50. This provides lower insertion stresses on the magnet 46, and reduced surface damage to the magnet 46 compared to having a plurality of the first plurality of rotor laminae 12 in an interference engagement.
Figures 6a and 6b illustrates, in part, a rotor 10 and the method of manufacturing the rotor 10. It will be understood that the method of manufacturing the rotor 10 of Figure 5 will comprise similar steps.
A plurality of first rotor laminae 12 and a plurality of second rotor laminae 32 are stacked to form a stack of first rotor laminae 12 and second rotor laminae 32, each of the first rotor laminae 12 having slots 16 therethrough, the slots 16 of each of the first rotor laminae 12 each having a first slot width 18, and each of the second rotor laminae 32 having slots 36 therethrough, the slots 36 of each of the second rotor laminae 32 each having a second slot width 38, the second slot width 38 being smaller than the first slot width 18.
In the manufacture of the rotor 10 the slots 16 of the first rotor laminae 12 are configured to overlay the slots 36 of the second rotor laminae 32, to form a rotor core 50 with rotor slots 56 therethrough, the rotor slots 56 being formed from the combination of slots 16 of the first rotor laminae 12 and the slots 36 of the second rotor laminae 32. Since the slot width 18 of the slots 16 of the first rotor laminae 12 are larger than the slot width 38 of the slots 36 of the second rotor laminae 32, the rotor slots 56 comprise varying width slots through the rotor core 50 in an area 60 encompassing the first lengthwise edges 20 of the slots 16 of each of the first plurality of rotor laminae 12 and the second lengthwise edges 40 of the slots 36 of each of the second plurality of rotor laminae 32 through the rotor core 50.
Once the first rotor laminae 12 and second rotor laminae 32 are correctly positioned relative to each other a magnet 46 is inserted into each of the rotor slots 56 in a first direction 58 to engage with a first lengthwise edge 40 of each of the slots 36 of each of the second plurality of rotor laminae 32 through the rotor core 50.
In the embodiment of Figure 6a, a magnet 46 is in the process of being inserted into a rotor slot 56, and in Figure 6b, the magnet 46 is fully inserted into the rotor slot 56. As the magnet 46 is inserted, the first lengthwise edge 40 of the slot 36 of each of the second plurality of rotor laminae 32 is deformed, or bent, by the interference engagement between the magnet 46 and the first and second lengthwise edges 40, 42 of the slot 36 of each of the second plurality of rotor laminae 32 through the rotor core 50.
Each deformed first lengthwise edge 40 of the slot 36 of each of the second plurality of rotor laminae 32 exerts a springback effect force on the magnet 46. The springback effect force is created by resilient deformation of the material of the second plurality of rotor laminae 32.
Therefore, when the first lengthwise edge 40 of the slot 36 of each of the second plurality of rotor laminae 32 is deformed to provide a springback effect force, the deformation is predominantly out of the plane of the respective rotor lamina 32 resulting in bending of the rotor lamina 32 to provide a springback load. The function of the springback effect from the overhanging first lengthwise edge 40 of the slot 36 of each of the second plurality of rotor laminae 32 is to ensure that the magnet 46 is constrained or prevented from moving in planar and axial directions. The engagement of the deformed, or bent, first lengthwise edge 40 of the slot 36 of each of the second plurality of rotor laminae 32 with the magnet 46 also provides for direct metal to metal contact allowing conduction of heat away from the magnet 46.
As shown in Figures 2 and 3, in segments 14-1 and 34-1, the slot 16 of each of the first rotor laminae 12 has a first slot length 19, in a lengthwise direction, orthogonal to the first slot width 18, and the slot 36 of each of the second rotor laminae 32 has a second slot length 39, in the lengthwise direction, orthogonal to the second slot width 38. Alternatively, or in addition, to the embodiments described above, the second slot length 39 may be smaller than the first slot length 19, and the magnet 46 is engaged with a first widthwise edge 41 of the slot 36 of each of the second plurality of rotor laminae 32 through the rotor core 50. The magnet 46 may be separated from a first widthwise edge 21 of the slot 16 of each of the first plurality of rotor laminae 12 through the rotor core 50. It is appreciated that the lengthwise edge and widthwise edge may also be referred to as a peripheral edge to encompass the immediate area of the lamina, starting from the lengthwise or widthwise edge surface, that deforms when an engagement occurs between the magnet 46 and the respective lamina. Merely as an example, in an embodiment wherein the magnet 46 may be engaged with the first lengthwise edge 20 of slot 16 of one or more of the first plurality of rotor laminae 12 through rotor core 50, the deformed area of each lamina starting from the first lengthwise edge 20 surface of slot 16 of one or more of the first plurality of rotor laminae 12 may also be referred to as first peripheral edge 20 of slot 16. Alternatively, or in addition, to the example above, in an embodiment wherein the magnet 46 is engaged with a first widthwise edge 41 of the slot 36 of one or more of the second plurality of rotor laminae 32 through the rotor core 50" the deformed area of each lamina starting from the first widthwise edge 41 surface of slot 36 of one or more of the second plurality of rotor laminae 32 may also be referred to as first peripheral edge 41 of slot 36.
For example, in one embodiment, the first slot width 18 of the first rotor laminae 12 is the same as the second slot width 38 of the second rotor laminae 32, and the first slot length 19 of the first rotor laminae 12, orthogonal to the first slot width 18, is larger than the second slot length 39 of the second rotor laminae 32, orthogonal to the second slot width 38. In such an arrangement a similar magnet engaging or retaining arrangement can be provided as described above, but, upon insertion of the magnet 46 into the rotor slot 56, the engagement or retention of the magnet 46 is in an axis orthogonal to the axis of engagement presented in the embodiments above, that is, the engagement with an inserted magnet 46 is by a first widthwise edge 41 of the slot 36 of each of the second plurality of rotor laminae 32 through the rotor core 50.
In some embodiments of the rotor 10, the second rotor laminae 32 are evenly distributed through the stack of first rotor laminae 12 and second rotor laminae 32. The second rotor laminae 32 may comprise one in every n laminae of the stack of first rotor laminae 12 and second rotor laminae 32, where n is a value between two and ten. For example, Figure 5 illustrates an example rotor 10 where n is two. Figures 6a and 6b illustrate an example rotor where n is 6. In other examples n may be 3, 4, 5, 7, 8, 9, or 10. A larger value of n allows for a rotor arrangement 10 with a smaller second slot width 38, such that upon insertion of a magnet 46 into the rotor slot 56, the deformation of the first lengthwise edge 40 of the slot 36 of each of the second plurality of rotor laminae 32 may be larger, with the deformed first lengthwise edge 40 of one lamina of the second plurality of rotor lamina 32 not interfering with a neighbouring lamina of the second plurality of rotor laminae 32.
It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.
STATEMENT OF INVENTION
The following paragraphs describe examples of various embodiments. Example 1 is a rotor comprising: a plurality of first rotor laminae, each of the first rotor laminae having a slot therethrough, the slot of each of the first rotor laminae having a first slot width; a plurality of second rotor laminae, each of the second rotor laminae having a slot therethrough, the slot of each of the second rotor laminae having a second slot width, the second slot width being smaller than the first slot width; the plurality of first rotor laminae and the plurality of second rotor laminae being stacked such that the slots of the first rotor laminae overlay the slots of the second rotor laminae, to form a rotor core comprising a stack of first rotor laminae and second rotor laminae with a rotor slot therethrough, the rotor slot having a varying width through the rotor core; and a magnet positioned in the rotor slot, engaged with a first lengthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core.
Example 2 may include the subject matter of example 1, and may further specify that the magnet is engaged with a second lengthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core, and wherein the engagement between the magnet and the first and second lengthwise edges of the slot of each of the second plurality of rotor laminae through the rotor core is an interference engagement.
Example 3 may include the subject matter of example 2, and may further specify that the magnet is engaged with a first lengthwise edge of the slot of one or more of the first plurality of rotor laminae through the rotor core.
Example 4 may include the subject matter of example 3, and may further specify that the magnet is engaged with a second lengthwise edge of the slot of each of the one or more of the first plurality of rotor laminae through the rotor core, and wherein the engagement between the magnet and the first and second lengthwise edges of the slot of the one or more of the first plurality of rotor laminae through the rotor core is an interference engagement.
Example 5 may include the subject matter of example 2, and may further specify that the magnet is separated from a first lengthwise edge of the slot of each of the first plurality of rotor laminae through the rotor core.
Example 6 may include the subject matter of example 5, and may further specify that the first lengthwise edge of the slot of each of the second plurality of rotor laminae is deformed by the interference engagement between the magnet and the first and second lengthwise edges of the slot of each of the second plurality of rotor laminae through the rotor core, each deformed first lengthwise edge of the slot of each of the second plurality of rotor laminae exerting a springback effect force on the magnet.
Example 7 may include the subject matter of any preceding example, and may further specify that the slot of each of the first rotor laminae has a first slot length orthogonal to the first slot width, and the slot of each of the second rotor laminae has a second slot length orthogonal to the second slot width, where the second slot length is smaller than the first slot length, and the magnet is engaged with a first widthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core.
Example 8 may include the subject matter of example 7, and may further specify that the magnet is separated from a first widthwise edge of the slot of each of the first plurality of rotor laminae through the rotor core.
Example 9 may include the subject matter of any preceding example, and may further specify that the rotor is formed to comprise a plurality of rotor poles, each rotor pole comprising one or more rotor slot therethrough in which a magnet is positioned.
Example 10 may include the subject matter of any preceding example, and may further specify that the second rotor laminae are evenly distributed through the stack of first rotor laminae and second rotor laminae.
Example 11 may include the subject matter of example 10, and may further specify that the second rotor laminae comprise one in every n laminae of the stack of first rotor laminae and second rotor laminae, where n is a value between two and ten.
Example 12 is a method of manufacturing a rotor, the rotor having a rotational axis, the method comprising: stacking a plurality of first rotor laminae and a plurality of second rotor laminae to form a stack of first rotor laminae and second rotor laminae, each of the first rotor laminae having a slot therethrough, the slot of each of the first rotor laminae having a first slot width, and each of the second rotor laminae having a slot therethrough, the slot of each of the second rotor laminae having a second slot width, the second slot width being smaller than the first slot width, wherein the slots of the first rotor laminae overlay the slots of the second rotor laminae, to form a rotor core with a rotor slot therethrough, the rotor slot having a varying width through the rotor core; and inserting a magnet into the rotor slot to engage with a first lengthwise edge of the slot of each of the second plurality of rotor laminae through the rotor core.
Example 13 is an electric machine comprising a rotor according to any of examples 1 to 11 and a stator.
Example 14 is a vehicle comprising an electric machine according to example 13.

Claims (13)

  1. CLAIMS1. A rotor comprising: a plurality of first rotor laminae, each of the first rotor laminae having a slot therethrough, the slot of each of the first rotor laminae having a first peripheral edge; a plurality of second rotor laminae, each of the second rotor laminae having a slot therethrough, the slot of each of the second rotor laminae having a second peripheral edge; the plurality of first rotor laminae and the plurality of second rotor laminae being stacked such that the slots of the first rotor laminae overlay the slots of the second rotor laminae, to form a rotor core with a rotor slot therethrough defined by the overlain slots, of the first and second rotor laminae; and a magnet positioned in the rotor slot, wherein at least a portion of the second peripheral edge of one or more of the second rotor laminae slots does not overlay the first peripheral edge of the first rotor laminae slots and extends into the rotor slot whereby said portion of the second edge is deformed by the magnet on insertion of the magnet into the rotor slot to engage and retain the magnet in the rotor slot.
  2. 2. A rotor as claimed in claim 1, wherein the first and second peripheral edges of the slots of the first and second laminae are in alignment with each other over a major part of the length of the stack of first and second laminae, to define the disposition of the magnet in the rotor core.
  3. 3. A rotor as claimed in claim 2, wherein there are more of said first rotor laminae in the stack than said second rotor laminae. 25
  4. 4. A rotor as claimed in claim 1, wherein at least a portion of the first peripheral edge of one or more of the first rotor laminae slots does not overlay the second peripheral edge of the second rotor laminae slots and extends into the rotor slot whereby said portion of the first peripheral edge is deformed by the magnet on insertion of the magnet into the rotor slot to engage and retain the magnet in the rotor slot.
  5. 5. A rotor as claimed in any of the preceding claims 1 to 4 wherein the magnet is engaged by a first of the slot of one or more of the first plurality of rotor laminae or second peripheral edge of the slot of one or more of the second plurality of rotor laminae through the rotor core, and wherein the engagement between the magnet and the first peripheral edge of slot or second peripheral edge of the slot is an interference engagement.
  6. 6. A rotor according to claim 5, wherein the first peripheral edge of slot or the second peripheral edge of the slot is deformed by the interference engagement between the magnet and the first peripheral edge or second peripheral edge, wherein each deformed peripheral edge of a slot of a plurality of rotor laminae exerts a springback effect force on the magnet.
  7. 7. A rotor according to any of the preceding claims, wherein a first peripheral edge refers to a widthwise edge of one or more of the first rotor laminae slots and a second peripheral edge refers to a widthwise edge of one or more of the second rotor laminae slots.
  8. 8. A rotor according to any of claims 1 to 6, wherein a first peripheral edge refers to a lengthwise edge of one or more of the first rotor laminae slots and a second peripheral edge refers to a lengthwise edge of one or more of the second rotor laminae slots.
  9. 9. A rotor according to any of the preceding claims, wherein the magnet is engaged by any one combination of first and/or second peripheral edges.
  10. 10. A rotor according to any of the preceding claims, wherein the rotor is formed to comprise a plurality of rotor poles, each rotor pole comprising one or more rotor slot therethrough in which a magnet is positioned.
  11. 11. An electric machine comprising a rotor according to any of claims 1 to 10 and a stator.
  12. 12. A vehicle comprising an electric machine according to claim 11.
  13. 13. A method of manufacturing a rotor, the rotor having a rotational axis, the method comprising: stacking a plurality of first rotor laminae to form a stack of first rotor laminae and second rotor laminae, each of the first rotor laminae having a slot therethrough, the slot of each of the first rotor laminae having a first peripheral edge and a plurality of second rotor laminae, each of the second rotor laminae having a slot therethrough, the slot of each of the second rotor laminae having a second peripheral edge the plurality of first rotor laminae and the plurality of second rotor laminae being stacked such that the slots of the first rotor laminae overlay the slots of the second rotor laminae, to form a rotor core with a rotor slot therethrough defined by the overlain slots of the first and second rotor laminae; and inserting a magnet positioned in the rotor slot, wherein at least a portion of the second peripheral edge of one or more of the second rotor laminae slots does not overlay the first peripheral edge of the first rotor laminae slots and extends into the rotor slot whereby said portion of the second edge is deformed by the magnet on insertion of the magnet into the rotor slot to engage and retain the magnet in the rotor slot.
GB2218452.7A 2022-12-08 2022-12-08 A rotor and a method of manufacture of a rotor Pending GB2625135A (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015076956A (en) * 2013-10-08 2015-04-20 株式会社ジェイテクト Rotor core and magnet embedded rotor
WO2018189822A1 (en) * 2017-04-12 2018-10-18 三菱電機株式会社 Ipm rotor
EP3876394A1 (en) * 2018-11-01 2021-09-08 Mitsubishi Electric Corporation Ipm rotor
JP2022155164A (en) * 2021-03-30 2022-10-13 株式会社アイシン Manufacturing method of rotor

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015076956A (en) * 2013-10-08 2015-04-20 株式会社ジェイテクト Rotor core and magnet embedded rotor
WO2018189822A1 (en) * 2017-04-12 2018-10-18 三菱電機株式会社 Ipm rotor
EP3876394A1 (en) * 2018-11-01 2021-09-08 Mitsubishi Electric Corporation Ipm rotor
JP2022155164A (en) * 2021-03-30 2022-10-13 株式会社アイシン Manufacturing method of rotor

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