JP2761851B2 - Manufacturing method of rotor with permanent magnet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotor core for a permanent magnet generator, and more particularly to a method for manufacturing a rotor with permanent magnets for fixing a plurality of permanent magnets around the outer periphery of the rotor core.

[0002]

2. Description of the Related Art Permanent magnet type rotors in which permanent magnets of a permanent magnet type generator are arranged on the outer periphery have conventionally been subject to simplification in the method of positioning, holding and fixing the permanent magnets arranged on the outer periphery. . As a fixing method, a method of bonding to a permanent magnet using an adhesive, or a method in which a permanent magnet is arranged on the outer periphery of a rotor and a semi-cured resin impregnated on the outer periphery having the same width as the width of the permanent magnet is impregnated. A method has been used in which the tape is repeatedly wound several times with a tape or the like, or a tape having a width smaller than the width of the permanent magnet, for example, a cloth tape is wound in a half-wrap manner and fixed. Also, after the permanent magnets are provided, the whole is molded with a synthetic resin. However, in recent years, the speed of rotating machines such as electric motors has been increased, so that the centrifugal force of the rotor has increased and the strength of holding and fixing the permanent magnet has become a problem. Further, the gap between the rotor and the stator is important in terms of performance. In particular, the displacement of the magnet in the direction of the rotation axis also affected the power generation efficiency.

For example, Japanese Patent Application Laid-Open No. 60-46757 discloses that a field iron core forming a rotor and a magnet are adhered and fixed with an adhesive or the like, and the outer periphery thereof is wound with a bind tape. A rotor has been proposed that heats and hardens the surface, cuts and polishes the surface of the bind tape and applies varnish to the surface to smooth the surface.However, the outer circumference of the end rings on both end plates is initially formed higher than the finished surface. Then, a step of polishing and cutting the surface after heating and melting to make the surface smooth is required. In Japanese Utility Model Laid-Open Publication No. 5-43451, a field iron core is laminated, magnets are arranged on the outer peripheral surface side, and end plates are arranged on both sides of the field iron core. To firmly clamp the iron core, fix it with a plurality of caulking pins, wind these outer metal binding wires,
A fixing method has been proposed in which the end of the binding wire is clamped to the caulking pins on both end plates. In addition, Tokuhei 6
In the invention described in JP-A-87-636, an arcuate permanent magnet is disposed on the outer peripheral surface of a field core, resin injection holes are provided on both end plates, and grooves are formed at the boundary between the permanent magnets. Sealing the boundary grooves by winding an adhesive tape so as to cover the parts, and then winding a semi-cured resin impregnated tape on the outside and filling the groove with resin from the resin injection hole of the end plate, This is a method for manufacturing a rotor with permanent magnets by heating the whole.

[0004]

When winding the semi-cured resin impregnated tape of the conventional rotor with a permanent magnet as described above, it is necessary to reduce the gap between the stator core and the permanent magnet as much as possible. It has been regarded as one of the biggest problems with generators. A permanent magnet attached to the outer peripheral surface has required a taping material that can withstand the centrifugal force of rotation and withstand temperature and secular change. In recent years, with the development of new materials,
A semi-cured resin impregnated tape has been used.
However, in order to wind such a wide semi-cured resin impregnated tape around a field core, it is common to spirally wind the tape. In this case, the clamping of the end of the semi-cured resin impregnated tape is problematic. there were. In the invention described in Japanese Utility Model Laid-Open Publication No. Hei 5-43451, after the binding wire is wound, the crimping pin is loosened to adjust the degree of pinching of the field core, and the tip of the binding wire is wound around the crimping pin. Had to be re-tightened.

Further, the conventional semi-cured resin impregnated tape is cured by heating the whole rotor in a drying furnace after winding, but such heating causes the resin to hang down due to a decrease in the viscosity of the resin, causing the resin to hang down. Without the cutting finish, the quality was not favorable. In addition, uniformity of the finished surface of the rotor and mass productivity have been important issues in manufacturing. The present invention improves such a complicated fixing method, winds a semi-cured resin-impregnated ultrafine yarn, and provides a method for manufacturing a rotor with a permanent magnet by a simple method that does not require a surface finishing treatment after curing. To provide. Another object of the present invention is to provide a permanent magnet which can fix a terminal treatment of a semi-hardened resin-impregnated ultrafine reinforcing yarn wound around the outer periphery thereof by a simple method after a permanent magnet is arranged on the outer peripheral surface of the rotor core. An object of the present invention is to provide a method for manufacturing a rotor with a magnet.

[0006]

SUMMARY OF THE INVENTION The present invention relates to a method of manufacturing a rotor with permanent magnets, wherein a plurality of permanent magnets are fixed on the outer periphery of a rotor core, and both ends of the permanent magnets are clamped and fixed by end plates. Laminated multiple rotor iron plates with trapezoidal grooves on the outer peripheral edge
To form a rotor core that is
Surface with a large number of wings, and at regular intervals near the periphery of the inner surface
When the fixing member is extended, a plurality of protrusions are provided between the fixing members.
Synthetic resin formed by integral molding with protruding arrangement
Arc-shaped on the outer periphery of this rotor core
After positioning the permanent magnets between the fixing members and arranging them at predetermined intervals, a tip of an ultrafine reinforcing yarn impregnated with a semi-cured resin is fixed to a part of the end plate, and this ultrafine reinforcing yarn is attached to the permanent magnet. The above object can be achieved by tightly winding the outer surface of the ultrafine reinforced yarn without gaps, heating and curing the surface of the ultrafine reinforced yarn, forming a synthetic resin thin film on the surface, and fixing the permanent magnet. Another object of the present invention is to provide a trapezoidal groove on the outer peripheral edge.
A rotor stacking process in which the obtained rotor iron plates are aligned and stacked to form a rotor core, and a large number of wing pieces are planted at regular intervals on the outer surface, and fixed members are arranged at regular intervals near the inner surface peripheral edge.
Overhangs and multiple protrusions are arranged between the fixing members.
End plates made of synthetic resin formed in a row and integrally formed are arranged on the outermost surfaces on both ends of the laminated rotor core, and bolts are inserted into bolt end holes of the end plate and the rotor core. And at the same time penetrate the rotating shaft through these shaft holes,
An assembling step of clamping and fixing the end plate from both sides by bolts and nuts, and a plurality of arc-shaped permanent magnets on the outer peripheral surface of the rotor core in a circumferential position by a fixing member between both end plates ;
Decisions and multiple protrusions protruding on the inner surface of the end plates
A magnet assembling step of forming a field iron core by fixing the magnet in the axial direction by raising and forming a field iron core, and a projection in which the tip of a microfine reinforcing yarn impregnated with a semi-cured resin is projected from an outer surface of the end plate. A winding step of tightly winding the ultrafine reinforced yarn on the outer peripheral surface of the permanent magnet while tightly applying tension thereto, and heat-fusing and curing the surface covered with the ultrafine reinforced yarn. It can also be achieved by a method for manufacturing a rotor with a permanent magnet, characterized by comprising a fusion hardening step.

[0007] In addition, an engaging pair is protruded from a peripheral edge of an inner surface of the end plate having a wing piece on an outer surface, and the engaging pair is opposed to each other and sandwiched from both axial sides of the rotor core. The above object can also be achieved by fixing the end plate by engaging the engaging portion of the engaging hand. In particular, the object can also be achieved by arranging a large number of protrusions for fixing the permanent magnet on the inner peripheral edge of the end plate and incorporating and fixing the permanent magnet.

[0008]

[Action] method of manufacturing a rotor with permanent magnets of this invention, the outer
Align multiple rotor iron plates with trapezoidal grooves on the periphery
And, after stacking, on its front and rear sides, a number of wings on the outer surface
Pieces, and fixed members are stretched at regular intervals near the periphery of the inner surface.
Protruding arrangement between the fixing members
The end plate made of synthetic resin
And put an arc-shaped permanent magnet on the outer circumference of this rotor core.
After positioning between the fixed members and arranging them at predetermined intervals,
Extra fine reinforcing yarn impregnated with semi-cured resin
Surface of the ultrafine reinforced yarn by heating and hardening.
To form a synthetic resin thin film on the surface
Is fixed, so the permanent magnet can be fixed stably.
be able to. Also, since a large number of wing pieces are formed on the outer surface of both side end plates, and fixed members and protrusions are formed integrally at fixed intervals inside by extraction molding , assembly of the rotor core is simplified.
Easy and secure mounting of permanent magnets
You. Further, the end plates are provided on both end surfaces of the laminated rotor core, and the rotor core is sandwiched and fixed with fasteners such as bolts, and a surrounding space between the outer peripheral surface of the rotor core and the both end plates. And end plate
Between the fixing members and the inner surface of the end plate.
The permanent magnet is securely fixed to form a field core, and on the outer peripheral surface side of the permanent magnet, a very fine reinforcing thread impregnated with semi-cured resin with its tip clamped to the fixed part of the end plate is closely spaced. It is possible to manufacture a rotor with a permanent magnet by winding and fixing a permanent magnet and fusing and hardening this coated ultrafine reinforcing yarn. And a surface finishing step such as cutting is not required.

Furthermore, since the ultrafine reinforcing yarn is wound around the outer peripheral surface, the terminal treatment is simpler and the winding tension is smaller as compared with a conventional tape having a wide width. The winding width can be easily adjusted by the number of turns. The thickness can be made constant by aligning and winding the whole. Moreover, since an end plate provided with wing pieces is used, there is no need to mount and arrange a cooling fan other than the end plate. In addition, a permanent magnet can be integrally fixed to the outer peripheral surface of the laminated rotor core with the end plates together with fixing of the end plates such as bolts and nuts, and the outer peripheral surface is impregnated with a semi-cured resin so as to be extremely fine. Since the reinforcing yarns are spirally aligned and wound, they can be wound honey without gaps, and when heated and cured in a drying oven, the surface cures smoothly and the quality is stable in terms of strength. It is a production method that can be obtained and easily mass-produced.

[0010]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a flowchart of a method for manufacturing a rotor with a permanent magnet according to the present invention. FIG. 2 is a perspective view of a rotor with a permanent magnet according to one embodiment manufactured by the manufacturing method of the present invention. FIG. 3 is a perspective view showing a method of winding the ultrafine reinforcing yarn in the method for manufacturing the rotor with permanent magnets of FIG. FIG. 4 is an enlarged view of a main part of the rotor with a permanent magnet of FIG. 2 before winding the ultrafine reinforcing yarn, (A) is a plan view, and (B) is a sectional view. 5A and 5B are enlarged explanatory views of an embodiment of a method for locking the microfine reinforced yarn end in the manufacturing method of the present invention. FIG. 5A is an enlarged perspective view of a main part, and FIG. 5B is an enlarged sectional view of the locking portion. .
FIGS. 6A and 6B are enlarged explanatory views of a main part of another embodiment of the method of locking the ultrafine reinforcing yarn end. FIG. 6A is an enlarged perspective view of the main part, and FIG. FIG. 7 is a front view of a rotor iron plate implemented in the rotor with a permanent magnet of the present invention.

An embodiment of a rotor with a permanent magnet manufactured by the method for manufacturing a rotor with a permanent magnet of the present invention will be described. Drilling trapezoidal grooves 3a on the outer peripheral surface,
The rotor iron plates 3 having the through holes 3b, 3b,... For fixing and the shaft holes formed in the center are laminated, and the end plates 4 are provided at both ends of the stacked rotor iron plates 3 in the axial direction. Abut 4
An arc-shaped permanent magnet 2 was arranged on the outer peripheral surface of the laminated rotor iron plate 3 to obtain a rotor main body 1. The end plate 4 has a large number of wing pieces 4a, 4a,... Erected at predetermined intervals on the outer surface, and a locking member 5 is protrudingly provided at a part of the periphery thereof. The locking member 5 is a screw rod or a nylon fastener. Also, a number of projections 11, 11,... On the outer peripheral edge of the inner surface of the end plate 4.
And are integrally formed by extraction molding.

Since the permanent magnet 2 is made of a well-known sintered alloy such as ferrite, it is very fragile and tends to adsorb metal powders or the like by magnetic force, so that it needs to be handled with care.
Numeral 6 denotes an engaging joint protruding from the inner side surfaces of both side end plates 4 and 4, and a meshing portion 7 is formed at a tip portion thereof. This engagement kumite 6
By firmly engaging the two, the rotor iron plate 3 is firmly held between the end plates 4 and 4. The engagement portion 7 of the engagement hand 6
And fix both ends with bolts 8 and nuts.
After fixing, the glass fiber thread 10 is used as the extra fine reinforcing thread of the non-magnetic material impregnated with the semi-cured resin, and the tip of the glass fiber thread 10 is wound around the locking member 5 of the end plate 4 and clamped. The glass fiber yarn 10 is densely wound around the permanent magnet 2 without any gap. The locking member 5 of the end plate 4 may be one in which a nylon fastener is inserted into a hole formed in a part of the end plate 4 as shown in FIG. 5B.

A method for manufacturing a rotor with a permanent magnet according to the present invention will be described. The rotor iron plate 3 predetermined number product layer <br/> to a constant thickness as shown in FIG. 7, the groove 3a of the formed trapezoidal in its outer peripheral surface, the inner side of the fixed frame or the end plate 3 to 3a · · Are engaged and fixed, the rotor iron plates 3, 3,... Are sandwiched, and the ends with the wing pieces 4a are attached to both outer sides thereof. The plates are arranged, the rotor iron plates 3, 3... Are assembled, bolts 8 are inserted into the bolt through holes 3b, 3b. In this manner, the rotor iron plates 3, 3,... Can be integrally fixed by the end plates 4, 4. On the outer peripheral surface of the rotor iron plate 3, the permanent magnet 2 is pushed between the end plates 4, 4, and is lightly hammered with, for example, a wooden hammer to be implanted on the inner edges of the end plates 4, 4.
・ ・ Be sure to hold and fix by.

Next, the leading end of the glass fiber thread 10 impregnated with the semi-cured resin is wound and locked on a locking member 5 provided on the outer surface of the end plate 4, and fitted into the buried groove 12 of the end plate 4. Then, the permanent magnet 2 is tightly wound around the outer peripheral surface, and its end is wound around the locking member 5 and fixed. For example, as shown in FIG. 5, a glass fiber thread 10 is attached to the locking member 5 of the nylon fastener at the beginning of winding.
After being wound into the buried groove 12 provided on the outer periphery of the end plate 4, as shown in FIG.
After being wound tightly and covering the front outer peripheral surface, the end of the glass fiber thread 10 is fixed by winding it around the locking member 5, and the whole is firmly fixed by heating. The entire rotor body 1 covered with the glass fiber yarn 10 is inserted into a drying furnace, heated at a predetermined temperature for a certain period of time, and then taken out. Is formed, and the glass fiber yarn 10 is formed.
And the whole is covered, and the permanent magnet 2 can be firmly fixed and held. At this time, the end of the glass fiber thread 10 is melted and firmly fixed in a state of being wound around the locking member 5. As a result, there is no fear of loosening of the yarn at the entire circumference and at the end even by the high-speed rotation of the rotor such as the generator.

The method of locking the tip of the glass fiber thread 10 to the locking member 5 of the end plate 4 is not limited to the method shown in FIG. 4, and for example, as shown in FIG. It can also be easily fixed by winding the glass fiber thread 10 around the integrally formed locking member 5.

[0016]

According to the method for manufacturing a rotor with a permanent magnet of the present invention, the outer peripheral surface of the permanent magnet disposed on the outer peripheral surface of the field iron core is made of an ultrafine reinforcing yarn impregnated with a semi-cured resin such as glass fiber yarn. Since the film is wound and coated and heated to form a film-like film on the outer peripheral surface of the permanent magnet, there is no need to cut the surface or remove burrs, etc. Not only can this be provided, but also the permanent magnet can be firmly held and fixed, the gap between the stator and the rotor can be made as small as possible, and a highly efficient generator can be manufactured.

[Brief description of the drawings]

FIG. 1 is a flowchart of a method for manufacturing a rotor with a permanent magnet according to the present invention.

FIG. 2 is a perspective view of a rotor with a permanent magnet of one embodiment manufactured by the manufacturing method of the present invention.

FIG. 3 is a perspective view showing a method of winding an ultrafine reinforcing yarn in the method of manufacturing the rotor with a permanent magnet of FIG. 2;

4 is an enlarged view of a main part of the rotor with a permanent magnet of FIG. 2 in a state before the ultrafine reinforcing yarn is wound, (A) is a plan view, and (B) is a cross-sectional view.

FIGS. 5A and 5B are enlarged explanatory views of an embodiment of a method of locking a microfine reinforced yarn end in the manufacturing method of the present invention, wherein FIG. 5A is an enlarged perspective view of a main part, and FIG. is there.

FIG. 6 is an enlarged explanatory view of a main part of another embodiment of the method of locking the terminal of the ultrafine reinforcing thread, wherein FIG.

FIG. 7 is a front view of a rotor iron plate implemented in the rotor with a permanent magnet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Rotor main body 2 ... Permanent magnet 3 ... Rotor iron plate 4 ... End plate 4a ... Wing piece 5 ... Locking member 6 ... Engagement joint 7 ... Meshing part 8 ... Bolt 10 ... Glass fiber thread 11 ... Projection

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Hirotaka Yamamoto 2-8-65 Yoshinodai, Kawagoe-shi, Saitama Denyo Co., Ltd. Saitama Plant (56) References JP-A-61-1246 (JP, A) JP-A-61-73559 (JP, A) JP-A-5-433751 (JP, U) JP-A 62-68454 (JP, U) JP-A 40-2907 (JP, Y1) (58) Survey Field (Int.Cl. ⁶ , DB name) H02K 1/27 501 H02K 15/03

Claims (3)

(57) [Claims] 1. A and laminating step for forming a rotor core by laminating by aligning a plurality of rotor iron plates having the outer peripheral edge trapezoidal groove, implanted many Tsubasahen at regular intervals on the outer surface , Outer edge of inner surface
Attach the fixing member at a certain interval in the vicinity and fix it.
By projecting multiple protrusions between members and integrally molding
The formed end plates made of synthetic resin are disposed on the outermost surfaces on both sides of the laminated rotor core, and bolts are inserted into the bolt through holes of the end plate and the rotor core, and the shaft holes are rotated. An assembling step of penetrating the shaft and pinching and fixing the end plate with bolts and nuts from both side surfaces, and a plurality of arc-shaped permanent magnets on the outer peripheral surface of the rotor core by a fixing member between both end plates. Position in the direction
And a plurality of protrusions protruding from the inner surface of both end plates
A magnet assembling step in which the field iron core is formed by being fixed in a more axial direction and arranged at regular intervals, and a projection in which the tip of a microfine reinforcing yarn impregnated with a semi-cured resin is provided on the outer surface of the end plate. A step of winding the ultrafine reinforced yarn tightly and tightly on the outer peripheral surface of the permanent magnet while applying tension to the outer surface of the permanent magnet; and heat-fusing and curing the surface covered with the ultrafine reinforced yarn. A method for manufacturing a rotor with a permanent magnet, comprising a fusion hardening step. To 2. A peripheral edge of the inner surface of said end plate, and out tension axially fixing member formed with engagement portions on the tip at regular intervals
The fixing members of the end plates are opposed to each other, sandwiched from both end faces of the rotor core, and the engaging portions of the fixing members are engaged.
2. The method according to claim 1, wherein the rotor core is fixed by using a rotor.
Method of manufacturing a rotor with permanent magnets according to. 3. An axial projection at the inner peripheral edge at regular intervals.
The fixing member and a plurality of protrusions arranged between the fixing members.
Raising and the end plates together form integrally with the wings projecting from the outside surface of the end plate and fixed in place at both ends of the rotor core, at each end plates, of the fixed member and the end plates Surrounded by the inner surface
The arc-shaped permanent magnet is incorporated in the space formed, and the extra fine reinforcing yarn impregnated with a semi-cured resin whose tip is clamped to a locking projection protruding from the outer surface of this end plate is used for the permanent magnet and the fixing member. Winding while applying tension tightly on the outer peripheral surface to form a field iron core, heat the entire field iron core, fuse the semi-cured resin on the outer surface to form a thin film,
The method for manufacturing a rotor with a permanent magnet according to claim 1, wherein the permanent magnet is fixed.