JP2010252560A - Method of molding lundell-type core for rotary electric machine, and pair of lundell-type core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of molding a Lundell-type core for a rotary electric machine, wherein the permanent magnet locking section can be molded accurately by a simple processing and a magnet can be inserted from the axial end. <P>SOLUTION: The permanent magnet locking section is provided, in such a manner that when the claw magnetic poles of a pair of Lundell-type cores are meshed alternately while inverting one core, the magnet mounting surface and the flange of one of the adjoining claw magnetic poles are arranged to face the magnet mounting surface and the flange of the other claw magnetic pole, and a magnet insertion space into which a magnet can be inserted from either axial end is formed. The magnet inserted from the axial end side is locked to the magnet-locking section in the magnet insertion space. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention combines a method for forming a Randell type iron core for a rotating electrical machine having means for locking a permanent magnet inserted between claw magnetic poles adjacent to each other in the circumferential direction, and a Randel type iron core formed by this method. The present invention relates to a pair of Rundel type iron cores.

  In vehicle alternators, it is generally widely used to increase the effective magnetic flux that contributes to power generation by mounting a permanent magnet between the claw magnetic poles of a pair of Randell type iron cores and reducing the leakage magnetic flux between the claw magnetic poles. ing.

  And it is common to form a magnet locking part on the outer peripheral part of the both sides in the circumferential direction of the claw magnetic pole so that the permanent magnet does not jump out of the claw magnetic pole with the rotation of the Landel type iron core. Patent Document 1 describes that the collar portion is provided over the entire length of the claw magnetic pole.

  On the other hand, as a method of forming the locking portions on the outer circumferential portions on both sides in the circumferential direction of the claw magnetic poles of this kind of Landel type iron core, it is conceivable to perform machine cutting. However, the applicant has been described in Patent Document 2 previously. As you can see, we are proposing manufacturing technology using forging technology. This forging technique has been devised so that a highly accurate product can be obtained without performing mechanical cutting with different characteristics during the manufacturing process. As shown in FIG. 9, a flange is formed on the peripheral edge of the claw pole. It is said.

Japanese Patent No. 3774987 Japanese Patent No. 3609745

  It has been demanded that a permanent magnet can be easily inserted between adjacent claw magnetic poles of a pair of Randell type iron cores to facilitate assembly work. According to the manufacturing technique shown in Patent Document 2, it is possible to provide a product having a high-precision magnet locking portion without performing mechanical cutting, but a permanent magnet between adjacent claw magnetic poles of a pair of Landel-type iron cores. Even if an attempt is made to insert and arrange from the axial direction, the bent portion formed at the connecting portion between the claw magnetic pole and the central boss portion at the center becomes an obstacle, and the permanent magnet cannot be inserted in the axial direction. In the case of this example, a magnet is installed in advance, and a pair of Randel iron cores are fitted into the magnet from the side later.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a rotating electrical machine that allows a magnet locking part by forging to be formed with high accuracy by simple processing and facilitates assembly work by allowing a magnet to be inserted from an axial end. The present invention intends to provide a method for forming a Landell type iron core for use and a pair of Landell.

The present invention is a method for forming a Landel type iron core provided with a magnet locking portion for locking a magnet inserted in the inner circumferential portion of both circumferential side surfaces of a claw magnetic pole portion,
The Randell type iron core is formed by roughly forging a blank by hot forging, directing a plurality of vertically extending claw magnetic pole portions and a central boss portion in the same direction, and an outer peripheral circle of the central boss portion. Forming the primary claw magnetic pole molded product in an integrated shape, and forming a central hole by punching in the center of the central boss portion of the primary claw magnetic pole molded product, and sizing the outer peripheral portion to secondary claw magnetic pole Covering the inner and outer peripheral portions and the central boss portion of the claw magnetic pole portion of the molded product, and the secondary claw magnetic pole molded product, and reaching the upper and lower ends of the claw magnetic pole portion between the inner peripheral edge portion of the claw magnetic pole portion Attach the upper die to the lower die that forms the forming space and hold the secondary claw pole molded product, press it, and reach the side of the claw pole by cold forging to the upper and lower ends in the axial direction of the claw pole part A smooth magnet mounting surface and a claw magnetic pole inner peripheral edge, and a circumferential direction from the peripheral edge of the claw magnetic pole inner peripheral edge. And a step of forming a tertiary claw magnetic pole molded product having a collar portion that reaches the upper and lower ends in the axial direction of the claw magnetic pole portion and continues to the smooth magnet mounting surface, A method for forming a Landel type iron core is provided, which is formed through a step of removing a slab to obtain a claw magnetic pole finished product.

  In the present invention, the central boss portion is composed of a central boss main body portion and a plate-like connecting portion to form a primary claw magnetic pole molded product, and the mold dividing position X is set to the plate thickness of the plate-like connecting portion. A method for forming a Landel-type iron core is provided, which is set to 1/2 or less with respect to the outer surface of the core.

  The present invention also forms a rotation balancing cutting surface having a ridge portion inclined inwardly at the root end portion of the claw magnetic pole portion, and the mold split position X is located inside the ridge line portion of the rotation balancing cutting surface. A method for forming a Landell-type iron core is provided.

The present invention is a pair of Randel type iron cores combining a claw magnetic pole portion extending in the axial direction from the outer periphery and a center boss portion integrated with the claw magnetic pole portion, and a Randell type iron core each having a central boss portion.
Each Landel type iron core extends from the inner peripheral edge of the claw magnetic pole inner edge to the inner peripheral direction on the claw magnetic pole side surface, the smooth magnet mounting surface reaching the upper and lower ends of the claw pole axial direction, and the claw magnetic pole inner peripheral edge. And it has a magnet locking part provided with a collar part that reaches the upper and lower ends in the axial direction of the claw magnetic pole part and continues to the smooth magnet mounting surface,
When a pair of Landel-type iron cores are turned over and the claw magnetic pole portions are alternately meshed, the adjacent claw magnetic pole portions are opposed to one magnet placement surface and the collar portion, and the other magnet placement surface and the collar portion. By being arranged, both magnet locking portions are arranged to face each other, so that a magnet insertion space portion that allows a magnet to be inserted from either end in the axial direction is formed. A pair of Landel-type iron cores are provided, in which the inserted magnets are locked to opposing magnet locking portions.

  The present invention also provides a vehicular AC generator rotor comprising the pair of Randell type iron cores.

  According to the present invention, the magnet insertion space that penetrates the upper and lower ends in the axial direction of the claw magnetic pole portion is formed, and the magnet can be inserted from any direction in the axial direction so that the claw magnetic poles of the pair of Randell type iron cores are alternately arranged. A method for forming a Randell type iron core used in a rotor for a rotating electrical machine in which a magnet can be easily inserted from the axial direction when the magnet is assembled and assembled, and a magnet is assembled from the axial direction when the Randem iron core formed by this method is assembled. A pair of randem iron cores that can be easily attached to the magnet locking portion can be provided.

  In addition, according to the present invention, there is provided a method for forming a Randel type iron core for a rotating electrical machine that can accurately form a permanent magnet locking portion by simple processing by setting a mold splitting position of a molding die to an appropriate position. Provided.

The front view of the blank material used in the Example of this invention. FIG. 3 is a structural diagram including a partial longitudinal section of a primary molded product in an example of the present invention. FIG. 3 is a structural diagram including a partial longitudinal section of a secondary molded product in an example of the present invention. The figure which shows implementation of the cold forge forming process in the Example of this invention. The top view seen from the top in the state which removed the upper metal mold | die in FIG. The front view which shows the state in which a burr | flash is produced | generated according to the parting position by implementation of a cold forging process. The side view in FIG. The longitudinal cross-sectional view of the tertiary molded product in the Example of this invention. The top view which looked at the tertiary molded article of FIG. 8 from upper direction. The perspective view which shows an assembly state in three dimensions. The figure which shows combining a tertiary molded product and inserting a magnet between these.

  Embodiments of the present invention will be described below with reference to the drawings.

  In FIG. 1, a blank material 1 is obtained by cutting a carbon steel for machine structure, which is usually a round steel, into dimensions based on design specifications. This blank material 1 is roughly struck by hot forging (molding) shown in FIG. 2, and a plurality of claw magnetic pole portions 2 and a central boss portion 3 shorter than the claw magnetic pole portions 2 in a uniaxial direction (upward in the drawing). Is pushed backward to obtain a substantially disc-shaped primary claw pole molded product 4 (hereinafter referred to as a primary molded product) in which the outer diameter portions are formed to be substantially vertical. The central boss part 3 includes a central boss main body part 3A and an integrated connecting part 5 on the side of the central boss main body part 3A. The claw magnetic pole part 2 of the primary molded product 4 has a plurality of claw magnetic pole parts arranged at equal intervals in the same manner as in FIG. 2 of Japanese Patent No. 3774987 (Patent Document 2). The bosses 3 are connected by a connecting part 5 having a connecting shape, and the claw magnetic pole part 2 has a substantially plate-like cross-sectional shape that is tapered from the base part toward the tip. An inclined surface 2 </ b> C that is inclined inward is formed on the base outer peripheral portion of the claw magnetic pole portion 2.

  The feature of the present embodiment with respect to the structure described in Patent Document 2 is that the magnet insertion space portion described in Patent Document 2 has a shape in which the claw magnetic pole portion is placed on the coupling portion of the central boss portion, Whereas the space portion penetrating in the axial direction is not formed, the outer circumferential circle of the central boss portion 2 is intended to form a magnet insertion space portion penetrating in the axial direction during final assembly, that is, The intermediate magnetic pole part 2 is integrated with the outer peripheral circle of the connecting part 5. Accordingly, the claw magnetic pole portion 2 is not structured to be placed above the connecting portion 5 but is forged into a shape attached to the side of the connecting portion 5 to form a magnet insertion space portion (FIG. 10) penetrating the upper and lower ends. It is easy to do. In this figure, the lower part of the claw magnetic pole part is referred to as a root part 2A, and the tip part 2B is referred to as an elongated tip part. In the figure, the outer peripheral surface 2D on the outer side of the claw magnetic part is referred to as the outer edge side, the inner side is referred to as the inner edge side, and the outer edge side is referred to as the side outer edge side (outer outer edge part). The inner edge side, the outer edge side, and the side outer edge extend in the circumferential direction. In such a shape, an inclined surface 2C inclined inward is formed on the outer side of the end portion of the root portion.

  Next, the primary molded product 4 is subjected to shot blasting and then subjected to a bond treatment for eliminating the frictional resistance between the molded product and the mold at the time of cold forging molding, and then, as shown in FIG. A secondary claw magnetic pole which is turned down and placed in a mold (not shown), and a through hole 6 serving as a rotation shaft mounting hole is formed by punching from the claw magnetic pole side opposite to the connecting portion 5 at the center of the boss portion 3. A molded product 8 (hereinafter referred to as a secondary molded product) is obtained. From the state when assembled in this figure, 2D is an outer peripheral surface, 2E is an inner peripheral surface, and the plane between 2D and 2E is a plane 2L across the upper and lower ends.

  And in the said process, the outer diameter sizing for the purpose of the improvement of the surface state of a molded article and the correction of a dimension is given simultaneously with the said punching.

  In the secondary molded product 8, the outer peripheral surface 2D and the inner peripheral surface 2E of the claw magnetic pole portion 2 and the inner side surface 5A of the central boss portion 3 are surrounded by the lower mold K1 as shown in FIGS. And placed in the lower mold K1. Here, in order to form a flange portion 2F constituting a magnet locking portion 20 described later on the claw magnetic pole portion 2, the lower mold K1 is formed with a step in relation to a molded product that is opposed and combined as described later. A space (not shown, but corresponding to the flange portion 2F) is formed. This step forming space is located on both sides of the claw magnetic pole portion 2 on the side outer edge side, and a space portion having a shape penetrating from the top to the bottom is formed in the claw magnetic pole portion 2. In this arrangement state, the claw magnetic pole portion 2 is held by the lower mold K1. In this state, the upper die K2 is coaxially disposed and lowered to close the central boss portion 3 and the outer surface 5B of the claw magnetic pole portion 2, and by applying pressure to the claw magnetic pole portion 2, the claw magnetic pole portion 2 is formed in the step forming space. Part of the material is filled with plastic flow, and the collar 2F extends in the circumferential direction on both sides of the claw magnetic pole part 2 from the upper end to the lower end and extends in the circumferential direction. The magnet mounting surface 2H, which is formed from the above-described plane 2L and is continuous with the collar portion 2F, is formed as a whole plane, and as a result, the magnet locking portion 20 is formed. In this way, a tertiary claw pole molded product 9 (hereinafter referred to as a tertiary molded product) with a magnet locking portion 20 is obtained.

  As described above, the magnet locking portion 20 is formed by cold forging on both sides of the claw magnetic pole portion 2 on the outer side of the side, the smooth magnet placement surface 2H reaching the upper and lower ends in the axial direction of the claw pole portion, and the claw magnetic pole. The inner edge portion is formed by a flange portion 2F that reaches the upper and lower ends in the axial direction of the claw magnetic pole portion and continues to the smooth magnet mounting surface 2H. Accordingly, when the collar portion 2F and the magnet placement surface 2H are described, the collar portion and the magnet placement surface formed on both sides of the claw magnetic pole portion 2 are meant. Here, the inclined surface formed corresponding to the aforementioned inclined surface 2C is represented by 2R. At the mold split position X of the tertiary molded product 8 formed in this way, burrs 7 are generated on the upper mold side. The processing direction of the burr 7 will be described.

  As shown in detail in FIG. 6 and FIG. 7, the tertiary molded product 9 obtained in this manner has the upper and lower mold split positions X on the inner peripheral surface 2 </ b> D of the base part of each claw magnetic pole part 2. It is on the surface of the formed inclined surface 2R (including the inclined surface start point).

  It is set so as to come inside the ridgeline part 2K of the formed press-molded surface (the end is a curved surface) 2R. A burr 7 is generated on the upper mold side of the parting position X. The aforementioned inclined surface 2R is a press-molded surface. The ridge line portion 2K is a starting point of the inclined point where the outer peripheral end surface of the connecting portion 5 is inclined inward. The position where this burr 7 is generated is the result of repeated trial production by the present inventors based on experience, and in the case where a tertiary molded product, which is a press-molded processed product by making the upper mold K2 shallow, is extracted from the mold. We have improved the so-called punching force and succeeded in lowering the processing pressure during molding, and have convinced that it can greatly contribute to the extension of mold life or work efficiency.

  Next, in FIG. 8 and FIG. 9 of the next process, the tertiary molded product 9 is finished by removing burrs 7 by cold working.

  The above-mentioned parting position X is preferably in a range t of ½ or less with respect to the outer surface 5B of the plate thickness T0 of the connecting plate constituting the connecting portion 5, and is press-molded surface 2R (press-molded curved surface 2R). The same position as the ridge line part 2K) is located slightly inside the ridge line part 2K. The press-molding surface 2R is cut to become a balancing cutting surface. This rotational balancing cutting surface is generally formed by cutting the entire circumference with an inclination of approximately 30 degrees with respect to the outer surface 5B of the connecting plate member 5.

  The tertiary molded product 9 is finished by removing burrs 7 by cold working in the next process shown in FIGS. 8 and 9, but the mold split position X is the outer peripheral surface 2D of the base part of the claw magnetic pole part 2 as described above. 2B, that is, the burrs 7 generated during the cold forging to obtain the tertiary molded product 9 are the rotational balancing cuttings. Almost removed during surface molding. Thus, there is no burr 7 on the outer peripheral surface 2D of the claw magnetic pole portion 2.

  The Rundel-type iron core formed in this way is generally used as a method for assembling the Landell iron core. As shown in FIG. 2 of Japanese Patent No. 3774987 cited in the prior art document, both sides of the rotating shaft are sandwiched between the field windings. One is inverted so that the claw magnetic poles of the tertiary molded product 8 combined with each other face each other and mounted on the rotating shaft (not shown) of the rotor of the vehicle high-flow generator. As shown in FIGS. 10 and 11, a pair of magnet locking portions 20 formed on the left and right sides are located between the claw magnetic poles 2 arranged alternately. A magnet body 11 that is magnetized in advance from either the left or right direction or magnetized after mounting is inserted into the magnet locking portion 20 to form a field pole.

The insertion of the magnet 11 will be described.
10 and 11 are diagrams showing a method of assembling the finished product 10 configured as described above so as to face each other vertically. As shown in these drawings, one finished product 10 (lower side) is arranged with the claw magnetic pole part 2 facing upward, and the other finished product 10 (upper) with the claw magnetic pole part 2 facing downward. Then, one claw magnetic pole part 2 of the other finished product 10 is disposed between the claw magnetic pole parts adjacent to one finished product. By this arrangement, the magnet locking portion 20 is set oppositely, and a magnet insertion space 30 is formed therebetween. In FIG. 11, the magnet 11 is shown by a solid line for clarifying the insertion state.

  In this case, as described above, the magnet locking portion 20 extends from the upper end to the lower end on both sides of the inner peripheral portion of the inner peripheral portion of the claw magnetic pole portion 2 and extends in the circumferential direction, and the flange portion 2F. The magnet pressing surface and the magnet mounting surface 2H on the inner surface of the collar portion 2F are all flat surfaces from the uppermost end to the lowermost position of both adjacent collars, There are no obstacles that can cause an insertion failure when inserting protrusions. The collar 2F is thin at this portion because the rotation balance cutting surface 2R is formed. When there is no rotation balance cutting surface 2R, the final end is also a flat surface having the same thickness.

  Therefore, when the two finished products 10 are combined vertically, both adjacent collar portions 2F are between the top and bottom of each claw magnetic pole portion 2, and the magnet mounting surface 2H is above each claw magnetic pole portion. It faces in a planar shape from the bottom to the bottom. As a result, a magnet insertion space 30 into which the plate-like magnet 11 having a certain thickness can be inserted from above or from the bottom is formed between the two magnet locking portions 20. The width of the magnet insertion space 30 in the direction perpendicular to the insertion direction is preferably equal.

  In other words, the magnet locking portion 20 has a magnet insertion space portion that allows the magnet 11 to be inserted from one end (for example, the upper end) and to be inserted from the other end (for example, the lower end). The magnet 11 inserted from the axial direction end side is locked in the magnet insertion space 12.

  The pair of Randel type iron cores configured as described above is desirably applied to a rotor of an automotive alternator.

  2 ... Claw magnetic pole part, 3 ... Central boss part, 4 ... Primary molded product, 5 ... Connection part, 2A ... Base part of claw magnetic pole part 2, 2B ... Tip part of claw magnetic pole part 2, 2C ... Inclined surface, 2D ... Outer peripheral surface, 2E ... inner peripheral surface, 2K ... ridge line part of press molding surface 2R, 2F ... collar, 2H ... magnet mounting surface, 2L ... outer peripheral portion, 2R ... press molding surface, cutting surface for rotational balancing, 5A ... inner surface of central boss part 3, 7 ... burr, 8 ... secondary claw pole molded product (secondary molded product), 9 ... tertiary claw pole molded product (tertiary molded product), 10 ... finished product, 11 ... magnet, 20 ... Magnet locking part, 30 ... Magnet insertion space part, K1 ... Lower mold, K2 ... Upper mold, X ... Split position of upper and lower molds.

Claims (5)

A method for forming a Landell-type iron core having a magnet locking portion for locking a magnet inserted in the inner peripheral portion of both circumferential side surfaces of a claw magnetic pole portion,
The Randell type iron core is formed by roughly forging a blank by hot forging, directing a plurality of vertically extending claw magnetic pole portions and a central boss portion in the same direction, and an outer peripheral circle of the central boss portion. Forming the primary claw magnetic pole molded product in an integrated shape, and forming a central hole by punching in the center of the central boss portion of the primary claw magnetic pole molded product, and sizing the outer peripheral portion to secondary claw magnetic pole Covering the inner and outer peripheral portions and the central boss portion of the claw magnetic pole portion of the molded product, and the secondary claw magnetic pole molded product, and reaching the upper and lower ends of the claw magnetic pole portion between the inner peripheral edge portion of the claw magnetic pole portion Attach the upper die to the lower die that forms the forming space and hold the secondary claw pole molded product, press it, and reach the side of the claw pole by cold forging to the upper and lower ends in the axial direction of the claw pole part A smooth magnet mounting surface and a claw magnetic pole inner peripheral edge, and a circumferential direction from the peripheral edge of the claw magnetic pole inner peripheral edge. And a step of forming a tertiary claw magnetic pole molded product having a collar portion that reaches the upper and lower ends in the axial direction of the claw magnetic pole portion and continues to the smooth magnet mounting surface, A method for forming a Landel type iron core, which is formed through a process of removing a slab to obtain a claw magnetic pole finished product.   2. The center boss portion according to claim 1, comprising a central boss main body portion and a plate-like connecting portion to form a primary claw magnetic pole molded product, and the mold dividing position X is defined as a plate thickness of the plate-like connecting portion. A method of forming a Landel type iron core, characterized in that it is set to 1/2 or less with respect to the outer surface of the core.   3. The rotary balancing cutting surface having a ridge line portion, which is inclined inwardly at a root end portion of the claw magnetic pole portion, is formed, and the mold dividing position X is located on the inner side of the ridge line portion of the rotational balancing cutting surface. A method for forming a Randell type iron core, characterized in that it is set to. In a pair of Randell type iron cores that combine a claw magnetic pole portion that extends in the axial direction from the outer periphery and a central boss portion that is integrated with the claw magnetic pole portion, respectively,
Each Landel type iron core extends from the inner peripheral edge of the claw magnetic pole inner edge to the inner peripheral direction on the claw magnetic pole side surface, the smooth magnet mounting surface reaching the upper and lower ends of the claw pole axial direction, and the claw magnetic pole inner peripheral edge. And it has a magnet locking part provided with a collar part that reaches the upper and lower ends in the axial direction of the claw magnetic pole part and continues to the smooth magnet mounting surface,
When a pair of Landel-type iron cores are turned over and the claw magnetic pole portions are alternately meshed, the adjacent claw magnetic pole portions are opposed to one magnet placement surface and the collar portion, and the other magnet placement surface and the collar portion. By being arranged, both magnet locking portions are arranged to face each other, so that a magnet insertion space portion that allows a magnet to be inserted from either end in the axial direction is formed. A pair of Landel type iron cores, wherein the inserted magnets are locked to the opposing magnet locking portions.   A rotor for a vehicle alternator comprising the pair of Landel type iron cores according to claim 4.

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