JP5560917B2 - Manufacturing method of rotor for rotating electrical machine and shaft material for rotating electrical machine - Google Patents

Description

  The present invention includes a method for manufacturing a rotor for a rotating electrical machine including an annular rotor core and a rotor shaft fitted inside the rotor core, and pressing the rotor core in the axial direction by a caulking portion formed on the rotor shaft. The present invention relates to a shaft material for a rotating electrical machine used in the manufacturing process.

  A rotating electrical machine used as a motor or a generator includes a rotor and a stator facing the rotor. Further, a structure including a rotatable rotor shaft and an annular rotor core fitted and fixed to the rotor shaft is known as a rotor. In such a rotor, a caulking portion is formed by deforming one end portion of the rotor shaft to the outer diameter side in a state where the rotor core is fitted to the outer diameter side of the rotor shaft, and the inner periphery of the rotor core is formed by the caulking portion. The structure which presses down the axial direction one end part of an edge part is considered. The caulking portion uses plastic deformation of metal and generates an axial force in the rotation axis direction from the rotor shaft to the rotor core.

  For example, Patent Document 1 describes a rotating electric machine including a shaft, a rotor core, and an end plate. The shaft is provided so as to be inscribed in the rotor core. The end plate is disposed so as to cover the end surface of the rotor core, and an inner peripheral end portion thereof is caulked in an annular shape by a flange of the shaft. The shaft has a flange at one end in the rotation axis direction of the shaft. The collar of the shaft has a wall thickness that becomes thinner from the root portion toward the tip portion. The collar curves outward in the radial direction and caulks the inner peripheral end of the end plate. Further, before the inner peripheral end of the end plate is caulked, the collar of the shaft is assumed to have a tapered shape that extends in the direction of the rotation axis. In addition, at the other end of the shaft in the rotation axis direction, a protruding portion protruding outward in the radial direction is provided at a portion opposite to the collar in the rotation axis direction.

Patent Document 2 also describes a rotating electrical machine including a rotor shaft, a rotor core, and an end plate, as in Patent Document 1. The end plate is fitted on the outer periphery of the rotor shaft and is in contact with the end surface of the rotor core. The caulking claw portion of the rotor shaft is bent to the outer peripheral side and is locked to the end plate while applying a force in the direction of the rotation axis to the end plate and the rotor core.
As prior art documents related to the present invention, there is Patent Document 3 in addition to Patent Documents 1 and 2.

JP 2005-168074 A JP 2009-124881 A JP 2004-248337 A

  In the case of the rotating electrical machines described in Patent Documents 1 and 2, the rotor core is fitted to the outer diameter side of the shaft, and the caulking portion such as a flange provided on the shaft is applied to the end plate while applying a force in the rotation axis direction. Locked to the end plate. The caulking portion is performed by pressing a jig such as a mandrel on the shaft in the direction of the rotation axis. In this case, it is conceivable to form the caulking portion by managing the stroke of the jig in the rotation axis direction with respect to the shaft.

  However, in such a configuration in which the conventional caulking portion is provided, if the shaft structure is not devised, the dimensional variation of the rotor components such as the dimensional variation when the rotor core is configured by a laminated body such as a magnetic steel sheet, or the assembly Due to the variation, the contact position between the axial end portion of the shaft constituting the caulking portion and the jig, that is, the positional relationship may vary. In this case, there is a possibility that the axial force, which is the force in the direction of the rotation axis acting on the rotor core from the caulking portion, varies depending on the product due to the change of the bending start point of the caulking portion. is there. For this reason, in the assembled state of the rotor, the `` caulking quality '' that the axial force and the removal load necessary for the rotor core to escape in the direction of the rotation axis with respect to the shaft varies, and the performance regardless of disturbance applied to the rotor There is a possibility that the robustness indicating the degree to which does not change decreases. For example, there is a possibility that the rotor core is fixed obliquely with respect to the shaft, and the product yield may be deteriorated.

  The caulking portion is provided by utilizing metal plastic deformation. For this reason, there is a possibility that a large load is required to secure a deformation amount capable of obtaining the required caulking performance. That is, in the conventional configuration, there is a possibility that the load when the shaft is stroked to provide the caulking portion may increase, and the equipment cost and cycle time become long, which may cause a cost increase. Further, when the rotor core includes a laminated steel plate, if the axial force acting on the rotor core in the direction of the rotation axis is excessively increased by the caulking portion, stress concentrates on a part of the weak steel plate and the rotor core is deformed. It cannot be said that there is no possibility. For this reason, the yield of the rotor product may be deteriorated.

  Under such circumstances, the present inventors have stabilized the caulking quality and improved robustness by devising the configuration before caulking formation of the rotor shaft in the configuration in which the axial force is applied to the rotor core by the caulking portion provided on the shaft. I came to think that it can improve the sex.

  On the other hand, Patent Document 3 includes a hydrodynamic bearing including a bottomed stepped sleeve having a cylindrical protrusion formed at the lower end, a flanged shaft inserted into the stepped sleeve, and a mounting hole. A spindle motor is described that includes a base plate having a cylindrical projection inserted into a mounting hole, a rotor, and a stator. The annular caulking portion formed on the lower surface of the columnar protrusion is plastically deformed until it comes into contact with a tapered surface provided on the inner peripheral surface of the mounting hole of the base plate. In addition, an annular groove is formed in the base portion of the cylindrical protrusion, and excessive deformation of the mounting hole is absorbed by the annular groove, so that deformation that causes the reference surface of the base plate to be out of order does not occur.

  In such a patent document 3, in the configuration in which the axial force is applied to the rotor core by the caulking portion provided on the shaft, means for stabilizing the caulking quality and improving the robustness are disclosed including matters suggesting it. Not. For example, the annular groove formed in the columnar protrusion does not stabilize the caulking quality of the caulking portion.

  The present invention provides a method for manufacturing a rotor for a rotating electrical machine and a shaft material for a rotating electrical machine, and stabilizes caulking quality and improves robustness in a configuration in which an axial force is applied to a rotor core by a caulking portion provided on the rotor shaft. With the goal.

A method of manufacturing a rotor for a rotating electrical machine according to the present invention includes an annular rotor core and a rotor shaft fitted inside the rotor core, and the rotor shaft is a fitting tube portion that fits the rotor core to the outer diameter side. And a protruding portion provided on one end side in the axial direction of the fitting cylinder portion so as to protrude toward the outer diameter side, and a curve formed on the other end side in the axial direction of the fitting cylinder portion so as to curve to the outer diameter side. a caulking portion, which is, the axial end portion of the inner circumferential end of the rotor core, seen including a crimping portion to press axially directly or through a end plate, between the projecting portion and the caulked portion in a method of manufacturing a rotary electric machine rotor pinching the rotor core, the shaft material for forming the rotor shaft, an annular shape so as recessed radially inward over the entire circumference on the outer peripheral surface of the axial end of the fitting cylindrical portion a cut-out step of providing a notch The annular notch includes a cylindrical surface that forms a bottom portion and a tapered surface that is continuous to the other end side in the axial direction that is the caulking portion side of the cylindrical surface and that is inclined toward the outer diameter side toward the side away from the cylindrical surface. And a caulking step for forming a caulking portion by applying an axial force to the other axial end portion of the shaft material with a jig and deforming the outer peripheral side in a state where the rotor core is fitted to the outer peripheral side of the fitting tube portion. The manufacturing method of the rotor for rotary electric machines characterized by including. In the method for manufacturing a rotor for a rotating electrical machine according to the present invention, preferably, the shaft material is an annular notch and is continuous with one end side in the axial direction opposite to the caulking portion of the cylindrical surface, and away from the cylindrical surface. In the cross-sectional shape related to the plane including the second tapered surface inclined toward the outer diameter side and including the central axis of the annular notch, the angle formed by the tapered surface and the cylindrical surface is formed by the second tapered surface and the cylindrical surface. The fitting tube portion of the shaft material includes an inner peripheral surface having an inner tapered surface whose diameter decreases toward one end in the axial direction on the inner diameter side of the portion including the second tapered surface.

  In the method for manufacturing a rotor for a rotating electrical machine according to the present invention, preferably, the notch step defines an axial dimension of the annular notch on the basis of a dimensional variation in the constituent parts of the rotor, and a shaft material for forming a caulking portion. The radial dimension of the annular notch is defined based on the target folding amount toward the outer diameter side.

  In the method for manufacturing a rotor for a rotating electrical machine according to the present invention, preferably, the caulking step forms the caulking portion so that the portion where the annular notch on the outer peripheral surface of the shaft material is formed becomes a starting point of bending.

  In the method for manufacturing a rotor for a rotating electrical machine according to the present invention, preferably, the rotor core includes a laminate of steel plates.

The shaft material for a rotating electrical machine according to the present invention is a shaft material for a rotating electrical machine that forms a rotor shaft used in the method for manufacturing a rotor for a rotating electrical machine according to the present invention, and the rotor core is fitted to the outer diameter side. a fitting tube that, a projecting portion that is provided so as to protrude to the outer diameter side in the axial direction one end side of the fitting tube, the entire circumference on the outer peripheral surface of the axial end of the fitting cylindrical portion An annular notch provided so as to be recessed toward the inner diameter side, and the annular notch is continuous with the cylindrical surface forming the bottom and the other end in the axial direction that is the caulking portion side of the cylindrical surface, and is on the side away from the cylindrical surface towards and a tapered surface inclined toward the outer diameter side, in use, an axial force is applied to the axial end of the annular notch of the shaft material by a jig to form a caulking portion by deforming the outer peripheral side Shah electric rotating machine, characterized in that to form the rotor shaft Te It is a door material.

  According to the method for manufacturing a rotor for a rotating electrical machine and the shaft material for a rotating electrical machine according to the present invention, the shaft material is provided with an annular notch. For this reason, in the configuration in which the axial force is applied to the rotor core by the caulking portion provided on the rotor shaft, when forming the caulking portion, the shaft material is easily deformed so that the portion where the annular notch is formed becomes the starting point of bending. . For this reason, the starting point of bending of the caulking portion is stabilized regardless of variations in the component parts, and it is not necessary to apply an excessively large load to the shaft material when forming the caulking portion. Therefore, the caulking quality can be stabilized and the robustness can be improved. Further, it is possible to suppress an excessive increase in cost and improve the yield of the rotor product.

1 is a schematic cross-sectional view showing an example of a rotor for a rotating electrical machine according to an embodiment of the present invention. It is the A section expanded sectional view of FIG. It is a figure which shows the shaft raw material which comprises the rotor shaft for comprising the rotor of FIG. It is sectional drawing of the shaft raw material of FIG. It is the B section expanded sectional view of Drawing 4. It is sectional drawing which shows a mode that a crimping jig is moved to the axial direction of a shaft raw material in the state which fitted the rotor core and the end plate to the outer diameter side of the shaft raw material of FIG.

  Hereinafter, embodiments according to the present invention will be described in detail with reference to the drawings. 1 to 6 show an example of an embodiment according to the present invention. The rotating electrical machine constructed by incorporating the rotor for rotating electrical machine of the present embodiment (hereinafter simply referred to as the rotor) is, for example, a first motor generator (MG1) or a second motor generator (MG2) that constitutes a drive device for a hybrid vehicle. ). Each of these motor generators has a function as a motor or a generator.

  Next, the rotating electrical machine will be described. The rotating electrical machine includes a stator (not shown) and a rotatable rotor 10 (FIG. 1) disposed opposite to the inner side in the radial direction of the stator. As shown in FIG. 1, the rotor 10 includes an annular rotor core 12, two end plates 14 and 16 disposed on both sides in the axial direction of the rotor core 12, and a rotor shaft 18 fitted inside the rotor core 12. Prepare. The rotor 10 is configured by fixing the rotor core 12 to the rotor shaft 18. Further, the rotor shaft 18 has a female spline on the inner peripheral surface of the center hole 20 provided in the center. In use, a male spline provided on a rotating shaft (not shown) is splined to the female spline.

  The rotor core 12 includes a laminate 22 formed by laminating a plurality of electromagnetic steel plates in the axial direction, and a permanent magnet 24 inserted and arranged in a plurality of locations in the circumferential direction of the laminate 22 in the axial direction. Each permanent magnet 24 is magnetized, for example, in the radial direction or in a direction inclined with respect to the radial direction.

  Further, the rotor shaft 18 has a fitting portion 26 that fits the rotor core 12 on the outer diameter side and has an outer peripheral surface that is a cylindrical surface, and an entire circumference on one end side in the axial direction of the fitting portion 26 (right end side in FIG. 1). The flange portion 28 is a protruding portion provided so as to protrude to the outer diameter side, and the other end side in the axial direction of the fitting portion 26 (left end side in FIG. 1) is curved to the outer diameter side over the entire circumference. And a crimped portion 30. The rotor shaft 18 includes a cylindrical main body portion 32 having a center hole 20, and a substantially disc-shaped connecting portion 34 that connects the fitting portion 26 and the main body portion 32.

  As shown in FIG. 2, the caulking portion 30 is an inner peripheral side of the rotor core 12 in a state where the rotor core 12 and the end plates 14 and 16 (see FIG. 1 for FIG. 1) are fitted to the outer diameter side of the fitting portion 26. The end portion in the axial direction is pressed in the axial direction via the end plate 14 on one side. That is, the caulking portion 30 causes the rotor core 12 and the end plates 14, 16 to be connected by the caulking portion 30 and the flange portion 28 by applying an axial force to the rotor core 12 via the end plate 14 on one side. It is clamped from both sides in the axial direction.

  Such a rotor 10 is manufactured using a shaft material 36 (FIG. 3) that is a material constituting the rotor shaft 18 and is a shaft material for a rotating electrical machine before the caulking portion 30 is formed. As shown in FIGS. 3 and 4, the shaft material 36 includes the fitting portion 26 that fits the rotor core 12 (FIG. 1) on the outer diameter side, and the center hole 20, as with the rotor shaft 18 after the caulking portion is formed. And a main body part 32 that is spline-coupled to a rotating shaft (not shown), and a connecting part 34 that connects the main body part 32 and the fitting part 26. Further, the shaft material 36 includes a flange portion 28 that is a protruding portion provided on one end side in the axial direction of the fitting portion 26 (the right end side in FIGS. 3 and 4) so as to protrude to the outer diameter side, and a fitting portion. 26 is provided with an annular notch 38 provided on the outer peripheral surface of the other end side 26 in the axial direction (left end side in FIGS. 3 and 4) so as to be recessed on the inner diameter side over the entire circumference. Further, as shown in FIG. 4, the fitting portion 26 is configured by integrally connecting a first tube portion 40 on one axial end side and a second tube portion 42 on the other axial end side. . The first cylinder part 40 is open at one axial end (the right end in FIG. 4), and the second cylinder part 42 is open at the other axial end (the left end in FIG. 4). Further, the inner peripheral surface of the second cylindrical portion 42 is a substantially tapered surface having an inner diameter that gradually decreases from the axially intermediate portion toward the back side.

  As shown in FIG. 5, the annular notch 38 is provided on the outer peripheral surface of the second cylindrical portion 42 so as to be recessed toward the inner diameter side over the entire periphery. The annular notch 38 includes a first surface S1 that is a bottom surface, and a second surface S2 and a third surface S3 that are a pair of side wall surfaces provided on both axial sides of the first surface S1. The first surface S <b> 1 is a cylindrical surface centered on the rotation axis O (FIG. 4) that is the central axis of the shaft material 36. Further, the second surface S2 on the one end side in the axial direction and the third surface S3 on the other end side in the axial direction are respectively tapered surfaces inclined with respect to the axial direction. In addition, the inclination angle α that is inclined with respect to the axial direction of the third surface S3 is smaller than the inclination angle β that is inclined with respect to the axial direction of the second surface S2 (α <β).

  The axial dimension L1, which is the axial interval between the opening ends of the annular notch 38 and the notch height of the annular notch 38, is a component of the rotor 10 that is caulked by the caulking portion 30 (FIGS. 1 and 2). That is, it is defined based on the dimensional variation of the rotor core 12 and the end plates 14 and 16. For example, when the total sum of the dimensional variations in the axial direction is P, for example, the notch height L1 is set larger than P. Further, the radial dimension L2 which is the depth of the annular notch 38 and the notch width of the annular notch 38 is a target bending amount to the outer diameter side of the shaft material 36 when the caulking portion 30 is formed, that is, a target It is defined based on the amount of deformation. The target folding amount is a folding amount necessary to make the caulking quality of the caulking portion 30 high, and the target folding amount and the radial dimension L2 are defined by a predetermined one-to-one correspondence, and the radial direction The dimension L2 is defined based on this correspondence from the target folding amount.

  The annular notch 38 is provided in the axially intermediate portion of the cylindrical outer peripheral surface of the second cylindrical portion 42 provided in the shaft material 36 so as to be depressed toward the inner diameter side over the entire circumference. That is, the cylindrical portions are continuous on both sides of the annular notch 38 in the axial direction.

  In the manufacturing method of the rotor 10 according to the present embodiment, in such a shaft material 36, a notch step is provided in which an annular notch 38 is provided on the outer peripheral surface on the other end side in the axial direction of the fitting portion 26 so as to be recessed toward the inner diameter side over the entire circumference. And a caulking step for forming the caulking portion 30 (FIGS. 1 and 2).

  In the notch step, as shown in FIG. 5, in the shaft blank 36, the second cylindrical portion 42 is provided at the other axial end, and the entire circumference of the cylindrical outer peripheral surface of the second cylindrical portion 42 is provided in the axial direction. An annular notch 38 that is recessed to the inner diameter side is provided. In the notch step, the annular notch 38 may be formed by machining or the like after the second cylindrical portion 42 is formed on the shaft material 36 together with the shape of other portions.

  Further, in the notch step, as described above, the axial dimension L1 of the annular notch 38 is defined based on the dimensional variations of the components of the rotor 10, and the shaft material 36 is formed on the outer diameter side when the caulking portion 30 is formed. The radial dimension L2 of the annular notch 38 is defined based on the target folding amount.

  Further, in the caulking step, as shown in FIG. 6, the caulking is performed in a state where the rotor core 12 and the end plates 14 and 16 (16 refer to FIG. 1) are fitted to the outer peripheral side of the fitting portion 26 constituting the shaft material 36. The jig 44 is displaced with respect to the shaft material 36 in the axial direction (the arrow direction in FIG. 6), and an axial force, which is an axial force, is applied to the distal end portion of the second cylindrical portion 42 by the caulking jig 44. As shown in FIG. 6, the caulking jig 44 has a curved portion 46 whose section is curved and recessed at a portion facing the second cylindrical portion 42. The curved portion 46 is formed in an annular shape as a whole, for example. For this reason, by displacing the caulking jig 44 in the direction of the arrow in FIG. 6, the distal end portion of the second cylindrical portion 42 is gradually deformed to the outer peripheral side (lower side in FIG. 6). As shown by a solid line from the two-dot chain line, the caulking portion 30 is formed, and the shaft material 36 becomes the rotor shaft 18. In this case, the end plate 14 is formed with a chamfer 48 such as a tapered surface on the outer surface in the axial direction of the inner peripheral end portion. For this reason, the caulking portion 30 is in surface contact with the chamfer 48 over the entire circumference. Note that the present invention is not limited to such a surface contact configuration, and the caulking portion 30 may be brought into line contact with the end plate 14. In any case, axial force in the axial direction (left-right direction in FIG. 2) acts on the rotor core 12 via the end plate 14 by the caulking portion 30.

  Further, in the caulking step, the caulking portion 30 is formed so that the portion where the annular notch 38 is formed on the outer peripheral surface of the shaft material 36 is the starting point of bending.

  In this way, the shaft material 36 is deformed to the outer peripheral side by applying axial force to the axial end of the shaft material 36 by the caulking jig 44 in a state where the rotor core 12 is fitted to the outer peripheral side of the fitting part 26 during use. By doing so, the caulking portion 30 is formed to constitute the rotor shaft 18.

  According to such a method for manufacturing the rotor 10 and the shaft material 36, the shaft material 36 is provided with the annular notch 38. For this reason, in the configuration in which the axial force is applied to the rotor core 12 by the caulking portion 30 provided on the rotor shaft 18, when the caulking portion 30 is formed, the shaft is formed so that the portion where the annular notch 38 is formed becomes the starting point of bending. The end portion of the material 36 is easily deformed. That is, the break point management of the caulking portion 30 can be easily performed. For this reason, the starting point of bending of the caulking portion 30 is stabilized and the shape of the caulking portion 30 can be made substantially the same regardless of variations in the component parts and the like. Therefore, the axial force, which is the force in the direction of the rotation axis O (FIG. 1) acting on the rotor core 12 from the caulking portion 30, can be prevented from varying depending on the product. As a result, in the configuration in which the axial force is applied to the rotor core 12 by the caulking portion 30 provided on the rotor shaft 18, the caulking quality can be stabilized and the robustness can be improved.

  Further, when the caulking portion 30 is formed, the amount of plastic deformation with respect to the load applied to the shaft material 36 by the caulking jig 44 can be increased, and it is not necessary to apply an excessively large load to the shaft material 36. For this reason, it can suppress that an installation cost and a cycle time increase significantly, and can suppress the raise of an excessive cost. Further, it is possible to effectively prevent excessive stress concentration from being generated from the caulking portion 30 to the end plates 14 and 16 and a part of the rotor core 12, and the end plate 14 and the rotor core 12 are formed of laminated steel plates. 16 and the rotor core 12 can be prevented from being deformed, and the product yield of the rotor 10 can be improved.

  Moreover, in this Embodiment, the rotor core 12 is set as the structure containing the laminated body 22 formed by laminating | stacking multiple electromagnetic steel plates. In such a laminated body 22, the tolerances of the magnetic steel sheets one by one are stacked, and the overall tolerance is likely to increase. For this reason, the contact position between the end portion of the rotor shaft 18 constituting the caulking portion 30 and the caulking jig 44 is likely to change due to a dimensional error of a component. In the present embodiment, since the annular cutout 38 is provided on the outer peripheral surface of the shaft material 36 as described above, the caulking quality can be stabilized and the robustness can be improved regardless of variations in the component parts. The effect becomes more prominent.

  In this embodiment, an axial force is applied from the caulking portion 30 to the rotor core 12 through the end plate 14, but at least the end plate 14 (see FIGS. 1 and 2) on the caulking portion 30 side is omitted. In addition, the rotor core 12 can be directly pressed in the axial direction by the caulking portion 30, and an axial force can be directly applied to the rotor core 12 from the caulking portion 30. In this case, the steel plate directly pressed by the caulking portion 30 may be lower in strength than the end plate. In this case, unlike the present invention, when a configuration in which the shaft material 36 is not provided with the annular notch 38 is adopted, a large force is directly applied from the caulking portion 30 to a part of the laminated body 22 due to a dimensional error of a component. May be added, and the steel sheet may be deformed, which may lead to deterioration of the product yield. On the other hand, when the configuration of the present invention is adopted, even when the end plate on the caulking portion 30 side is omitted as described above and the rotor core 12 is pressed directly in the axial direction by the caulking portion 30, The yield can be improved by effectively preventing deformation of the steel sheet.

  In the embodiment shown in each of the above drawings, a part of the inner peripheral surface of the second cylindrical portion 42 in which the annular notch 38 is provided on the outer peripheral surface is a substantially tapered surface. However, the inner peripheral surface of the cylindrical portion in which the annular notch 38 is provided on the outer peripheral surface may be a simple cylindrical surface as a whole. Further, in the shaft material 36 shown in FIG. 4 described above, the end portion of the second cylindrical portion 42 on the front end side relative to the annular notch 38 is not limited to a configuration in which the radial thickness is constant, It can also be configured such that the wall thickness gradually decreases as it goes to. Further, a tapered surface inclined with respect to the axial direction is provided on the inner peripheral surface of the end portion on the tip side of the annular notch 38 of the second cylindrical portion 42, and the caulking jig 44 is formed on the tapered surface when the caulking portion 30 is formed. It can also be possible to press.

  In addition, the structure of the shaft raw material 36 which comprises the rotor shaft 18 is not limited to the structure shown in said FIG. 3 to FIG. 6, The fitting part which fits the rotor core 12, and protrusion parts, such as a flange part And a cylindrical portion for constituting the caulking portion, and a configuration in which an annular notch is provided on the outer peripheral surface of the cylindrical portion.

  Further, the rotor core 12 is not limited to the one including the laminated body 22 of steel plates, and the rotor core 12 may be constituted by a dust core formed by pressure-forming magnetic powder, for example.

  DESCRIPTION OF SYMBOLS 10 Rotor, 12 Rotor core, 14, 16 End plate, 18 Rotor shaft, 20 Center hole, 22 Laminated body, 24 Permanent magnet, 26 Fitting part, 28 Flange part, 30 Caulking part, 32 Main body part, 34 Connection part, 36 Shaft material, 38 annular notch, 40 first cylinder part, 42 second cylinder part, 44 caulking jig, 46 bending part, 48 chamfering.

Claims (6)

An annular rotor core;
A rotor shaft fitted inside the rotor core,
The rotor shaft has a fitting cylinder portion that fits the rotor core to the outer diameter side,
A protruding portion provided to protrude to the outer diameter side on one end side in the axial direction of the fitting cylindrical portion ;
A caulking portion formed to bend toward the outer diameter side over the entire circumference on the other end side in the axial direction of the fitting cylinder portion , and directly or end plate the end portion in the axial direction of the inner peripheral side end portion of the rotor core look including a crimping portion to press axially through a method of manufacturing a rotary electric machine rotor sandwiching a rotor core between the projecting portion and the caulked portion,
In the shaft material forming the rotor shaft, a notch providing a cyclic notch so as to be recessed radially inward over the entire circumference on the outer peripheral surface of the axial end of the fitting cylinder, annular cut-out forms the bottom A notch step that includes a cylindrical surface that is continuous with the other end side in the axial direction that is the caulking portion side of the cylindrical surface, and that is inclined toward the outer diameter side toward the side away from the cylindrical surface;
A caulking step of forming a caulking portion by applying an axial force to the other axial end portion of the shaft material with a jig and deforming it to the outer peripheral side with the rotor core fitted to the outer peripheral side of the fitting cylinder portion. A method for manufacturing a rotor for a rotating electrical machine. In the manufacturing method of the rotor for rotating electrical machines according to claim 1,
The shaft material includes a second tapered surface that is continuous with the one end side in the axial direction that is opposite to the caulking portion of the cylindrical surface in the annular notch, and is inclined toward the outer diameter side toward the side away from the cylindrical surface.
  In the cross-sectional shape related to the plane including the central axis of the annular notch, the angle formed by the tapered surface and the cylindrical surface is larger than the angle formed by the second tapered surface and the cylindrical surface,
The fitting cylinder portion of the shaft material includes an inner peripheral surface having an inner tapered surface whose diameter decreases toward one end in the axial direction on the inner diameter side of the portion including the second tapered surface. Production method. In the manufacturing method of the rotor for rotary electric machines according to claim 1 or 2 ,
The notch step defines the axial dimension of the annular notch based on the dimensional variation of the rotor components, and the radial direction of the annular notch based on the target folding amount to the outer diameter side of the shaft material to form the caulking portion A method for manufacturing a rotor for a rotating electrical machine, characterized in that a dimension is defined. In the manufacturing method of the rotor for rotary electric machines of any one of Claims 1-3 ,
In the caulking step, the caulking portion is formed such that the portion where the annular cutout is formed on the outer peripheral surface of the shaft material is a starting point of bending. In the manufacturing method of the rotor for rotary electric machines according to any one of claims 1 to 4 ,
The method for manufacturing a rotor for a rotating electrical machine, wherein the rotor core includes a laminate of steel plates. A shaft material for a rotating electrical machine that forms a rotor shaft used in the method for manufacturing a rotor for a rotating electrical machine according to claim 1,
A fitting tube portion for fitting the rotor core to the outer diameter side;
A protruding portion provided to protrude to the outer diameter side on one end side in the axial direction of the fitting cylindrical portion ;
Includes a fitting tube annular notch Metropolitan to outside peripheral surface of the axial end provided so as to be recessed radially inward over the entire circumference of
The annular notch includes a cylindrical surface that forms a bottom portion, and a tapered surface that is continuous with the other end side in the axial direction that is the caulking portion side of the cylindrical surface and is inclined toward the outer diameter side toward the side away from the cylindrical surface,
A shaft for a rotating electrical machine characterized by forming a rotor shaft by applying an axial force to an axial end portion on the annular notch side of a shaft material by a jig and using a jig to form a caulked portion during use. Material.

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