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WO2024127833A1 - Procédé de fabrication de rotor pour machine électrique rotative - Google Patents

Procédé de fabrication de rotor pour machine électrique rotative Download PDF

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Publication number
WO2024127833A1
WO2024127833A1 PCT/JP2023/039035 JP2023039035W WO2024127833A1 WO 2024127833 A1 WO2024127833 A1 WO 2024127833A1 JP 2023039035 W JP2023039035 W JP 2023039035W WO 2024127833 A1 WO2024127833 A1 WO 2024127833A1
Authority
WO
WIPO (PCT)
Prior art keywords
magnet
resin material
resin
rotor
permanent magnet
Prior art date
Application number
PCT/JP2023/039035
Other languages
English (en)
Japanese (ja)
Inventor
俊之 佐分利
Original Assignee
株式会社アイシン
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 株式会社アイシン filed Critical 株式会社アイシン
Publication of WO2024127833A1 publication Critical patent/WO2024127833A1/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner 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
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets

Definitions

  • This disclosure relates to a method for manufacturing rotors for rotating electrical machines.
  • a known technique for manufacturing rotors for rotating electrical machines involves inserting a solid resin material into a magnet hole, then inserting a preheated permanent magnet into the magnet hole to melt at least a portion of the resin material, and then further heating the core to harden the resin material.
  • the present disclosure aims to insert a permanent magnet into a desired position within a magnet hole and fix it in place with a resin material.
  • a method for producing a rotor core having an axial magnet hole and a permanent magnet insertable into the magnet hole includes the steps of: a resin injection step of injecting a resin material having a different melting temperature and hardening temperature in a molten state into the magnet hole; a magnet insertion step of inserting the permanent magnet into the magnet hole in such a manner that the molten resin material reaches around the permanent magnet after the resin injection step; and a resin hardening step of hardening the resin material extending around the permanent magnets inserted in the magnet insertion step.
  • the present disclosure allows a permanent magnet to be inserted into a desired position within a magnet hole and secured in place with a resin material.
  • FIG. 1 is a cross-sectional view showing a schematic cross-sectional structure of a motor according to an embodiment
  • 2 is a cross-sectional view of a rotor (a cross-sectional view taken along a plane perpendicular to the axial direction).
  • FIG. FIG. 3 is an enlarged view of a portion relating to one magnetic pole shown in FIG. 2 .
  • FIG. 4 is a schematic cross-sectional view taken along line AA in FIG. 4 is a flowchart illustrating a schematic flow of a method for manufacturing a motor according to the present embodiment.
  • FIG. FIG. 11 is an explanatory diagram of a nozzle positioning step.
  • FIG. FIG. FIG. 11 is an explanatory diagram of a preferred example of a magnet insertion step, and is a cross-sectional view showing a schematic state before the start of the step.
  • FIG. 11 is a schematic cross-sectional view for explaining a resin curing step.
  • FIG. 1 is a cross-sectional view that shows a schematic cross-sectional structure of a motor 1 according to one embodiment.
  • FIG. 2 is a cross-sectional view of a rotor 30 (a cross-sectional view taken along a plane perpendicular to the axial direction). Note that in FIG. 2 and other figures, for ease of viewing, reference symbols may be given to only some of the parts that have the same attributes when there are multiple parts.
  • the rotating shaft 12 of the motor 1 is shown.
  • the axial direction refers to the direction in which the rotating shaft (center of rotation) 12 of the motor 1 extends
  • the axial outer side refers to the side away from the axial center of the rotor core 32
  • the axial inner side refers to the side toward the axial center of the rotor core 32.
  • the radial direction refers to the radial direction centered on the rotating shaft 12
  • the radial outer side refers to the side away from the rotating shaft 12
  • the radial inner side refers to the side toward the rotating shaft 12.
  • the circumferential direction corresponds to the direction of rotation around the rotating shaft 12.
  • Motor 1 may be a motor for driving a vehicle, such as that used in a hybrid vehicle or an electric vehicle. However, motor 1 may also be used for any other purpose.
  • the motor 1 is an inner rotor type, and the stator 21 is arranged to surround the radial outside of the rotor 30.
  • the radial outside of the stator 21 is fixed to the motor housing 10.
  • the stator 21 has a stator core 211 made of, for example, a circular ring-shaped laminated steel plate of a magnetic material, and a plurality of slots (not shown) are formed on the radial inside of the stator core 211, around which the coils 22 are wound.
  • the rotor 30 is positioned radially inside the stator 21.
  • the rotor 30 comprises a rotor core 32, a rotor shaft 34, end plates 35A and 35B, and a permanent magnet 62.
  • the rotor core 32 is fixed to the radially outer surface of the rotor shaft 34 and rotates integrally with the rotor shaft 34.
  • the rotor core 32 has an axial hole 320 (see FIG. 2), into which the rotor shaft 34 is fitted.
  • the rotor core 32 may be fixed to the rotor shaft 34 by shrink fitting, press fitting, or the like.
  • the rotor core 32 may be connected to the rotor shaft 34 by a key connection or a spline connection.
  • the rotor shaft 34 is rotatably supported in the motor housing 10 via bearings 14a, 14b.
  • the rotor shaft 34 defines the rotating shaft 12 of the motor 1.
  • the rotor core 32 is formed, for example, from laminated steel plates of a circular magnetic material. Permanent magnets 62 (see FIG. 2) are embedded inside the rotor core 32. That is, the rotor core 32 has magnet holes 322 (see FIG. 2) that penetrate in the axial direction, and the permanent magnets 62 are inserted and fixed into the magnet holes 322.
  • the rotor core 32 may be formed from a green compact in which magnetic powder is compressed and solidified.
  • the rotor core 32 has a rotationally symmetric shape centered on the rotating shaft 12 when viewed in the axial direction.
  • the rotor core 32 has a shape in which each set of permanent magnets 62 overlaps every 45 degrees of rotation about the rotating shaft 12.
  • the multiple permanent magnets 62 may be made of neodymium or the like.
  • the multiple permanent magnets 62 are arranged in pairs when viewed in the axial direction. In this case, a common magnetic pole is formed between the pair of permanent magnets 62.
  • the multiple permanent magnets 62 are arranged in a manner in which S poles and N poles appear alternately in the circumferential direction. In this embodiment, the number of magnetic poles is eight, but the number of magnetic poles is arbitrary.
  • the permanent magnets 62 have the same linear shape when viewed in the axial direction, but they may have different shapes.
  • At least one of the permanent magnets 62 may have an arc shape when viewed in the axial direction.
  • another pair of permanent magnets may be arranged at a different radial position from the pair of permanent magnets 62.
  • the fixing structure and the like related to the permanent magnets 62 described below can be similarly applied to other permanent magnets.
  • FIG. 1 shows motor 1 having a specific structure
  • the structure of motor 1 is not limited to such a specific structure.
  • rotor shaft 34 is hollow, but it may be solid.
  • FIG. 3 is a plan view showing a schematic of the fixing structure of the permanent magnets 62 in the rotor core 32 according to this embodiment, and is an enlarged view of a portion relating to one magnetic pole shown in FIG. 2.
  • the configuration relating to one magnetic pole is basically symmetrical with respect to the d-axis (written as "d-axis" in English in FIGS. 2 and 3).
  • the d-axis corresponds to the direction of the magnetic field generated by the permanent magnets 62 arranged in the rotor 30.
  • FIG. 4 is a schematic cross-sectional view taken along line A-A in FIG. 3.
  • the Z direction is defined along with its two sides, the Z1 side and the Z2 side.
  • the Z direction is parallel to the axial direction of the motor 1.
  • the Z direction corresponds to the up-down direction, but this may be different from the up-down direction when the motor 1 is mounted on the vehicle.
  • the Z1 side and the Z2 side represent a relative positional relationship, with the Z1 side corresponding to the upper side.
  • the permanent magnets 62 are fixed in the magnet holes 322 of the rotor core 32 by a resin material layer 72.
  • the resin material layer 72 may be formed, for example, from a thermosetting resin or from a thermoplastic resin. A method for forming the resin material layer 72 will be described in detail later.
  • the resin material layer 72 is bonded, for example, to both the permanent magnet 62 and the rotor core 32 with an anchor effect.
  • the anchor effect on the permanent magnet 62 side may be achieved by roughening the insulating layer (not shown) provided as a surface coating for the permanent magnet 62.
  • the anchor effect on the rotor core 32 side may be achieved by forming the rotor core 32 from laminated steel plates.
  • the resin material layer 72 may be joined to the permanent magnet 62 in such a manner that both axial end faces 621, 622 of the permanent magnet 62 are exposed.
  • the resin material layer 72 may be joined only to the side surface of the permanent magnet 62 in a direction intersecting the axial direction.
  • the material related to the resin material layer 72 may be attached to the end face 622 of both axial end faces 621, 622 of the permanent magnet 62.
  • the resin material layer 72 may extend between the permanent magnet 62 and the peripheral wall surface of the magnet hole 322 in such a manner that the resin material layer 72 fills the space between the permanent magnet 62 and the peripheral wall surface of the magnet hole 322 without any gaps.
  • the resin material layer 72 is bonded to the permanent magnet 62 in such a manner that it surrounds the permanent magnet 62 over its entire circumference when viewed in the axial direction. That is, the resin material layer 72 is bonded to all four faces of the permanent magnet 62.
  • the resin material layer 72 is bonded to the peripheral wall surface of the magnet hole 322 over its entire circumference when viewed in the axial direction. That is, the resin material layer 72 is bonded to the magnet hole 322 over its entire circumference. This allows the permanent magnet 62 to be fixed more firmly to the rotor core 32 than when the resin material layer is bonded only to a part of the entire circumference of the permanent magnet 62.
  • the axial direction refers to the direction in which the central axis I0 of the rotor core 32 (workpiece W) corresponding to the rotating shaft 12 of the motor 1 extends
  • the radial direction refers to the radial direction centered on the central axis I0 of the rotor core 32. Therefore, the radially outer side refers to the side away from the central axis I0 of the rotor core 32, and the radially inner side refers to the side toward the central axis I0 of the rotor core 32.
  • the circumferential direction corresponds to the direction of rotation around the central axis I0 of the rotor core 32.
  • FIG. 5 is a flow chart showing the outline of the flow of the manufacturing method of the motor 1 according to this embodiment.
  • FIGS. 6 to 10 are explanatory diagrams of specific steps in the manufacturing method shown in FIG. 5.
  • FIG. 6 is an explanatory diagram of the work supporting step
  • FIG. 7 is an explanatory diagram of the nozzle positioning step
  • FIG. 8 is an explanatory diagram of the resin injection step
  • FIG. 9 is an explanatory diagram of the magnet insertion step, each of which is a cross-sectional view showing a schematic state after the steps. Note that FIG. 8 shows a schematic state after the resin injection step for one magnet hole 322.
  • FIG. 10 is an explanatory diagram of a preferred example of the magnet insertion step, and is a cross-sectional view showing a schematic state before the start of the step.
  • FIG. 11 is a schematic cross-sectional view for explaining the resin hardening step.
  • This manufacturing method first prepares the permanent magnets 62 and includes a steel plate lamination process (step S1) in which multiple steel plates 3250 are laminated as a preparation process for preparing the workpiece W of the rotor core 32.
  • the workpiece W of the rotor core 32 may be a unit of the laminated block.
  • the manufacturing method includes a workpiece supporting step (step S2) of placing the workpiece W on the support jig 120, as shown in FIG. 6.
  • the support jig 120 is one element of the manufacturing apparatus 100, and may support the workpiece W while transporting the workpiece W between each process.
  • the support jig 120 may be in the form of a movable conveyor or the like, or may be in the form of a transport tray that is transported by being placed on a conveyor or the like.
  • the support jig 120 may also be configured to be grasped by a transport robot.
  • the manufacturing method includes a preheating process (step S3) (an example of a heat application process) of preheating the workpiece W.
  • the preheating process may be achieved by an induction heating device, a heating furnace, or the like.
  • the induction heating device may be disposed radially inside and/or radially outside the rotor core 32 of the workpiece W.
  • the preheating process (step S3) may be achieved by using a heating device 160 (see Figures 10 and 11) described below.
  • the manufacturing method includes a nozzle positioning step (step S4) in which the nozzle 131 of the resin placement device 130 is positioned within the magnet hole 322 of the workpiece W on the support jig 120.
  • the nozzle 131 of the resin placement device 130 may be positioned so that it can be inserted into and removed from the magnet hole 322 by vertical movement.
  • the manufacturing method includes a resin injection process (step S5) in which the resin material 90 for forming the above-mentioned resin material layer 72 is placed in the magnet hole 322 in a molten state.
  • the resin material 90 may be molten in a resin injector (not shown) and introduced to the nozzle 131.
  • the nozzle 131 may eject the molten resin material 90 from the outlet 1310 with the outlet 1310 inserted into the magnet hole 322.
  • the amount of heat dissipation can be reduced (and therefore the molten state can be easily maintained), and the occurrence of resin material 90 that does not enter the magnet hole 322 due to scattering or the like can be prevented.
  • the resin material 90 is a thermosetting resin material with a relatively low viscosity, and is injected in a pre-hardened state (a flowable molten state). Therefore, the resin material 90 injected into the magnet hole 322 flows (falls) downward due to its own weight, and accumulates with the surface of the support jig 120 as the bottom surface.
  • the resin material 90 preferably has a melt viscosity of 500 Pa ⁇ s or more, and more preferably has a melt viscosity of 700 Pa ⁇ s or more, at 90° C. and a shear rate of 1/s.
  • a resin material 90 may include a crystalline radically polymerizable composition as described in JP 2021-161164 A, the disclosure of which is incorporated herein by reference.
  • the resin material 90 has a characteristic that the melting temperature and the curing temperature are different.
  • the resin material 90 described in JP 2021-101605 A the disclosure of which is incorporated herein by reference, may be used.
  • the melting temperature (melting start temperature) is, for example, 60° C.
  • the curing temperature (curing start temperature) is, for example, 120° C.
  • the resin temperature heated by the resin injection machine may be a temperature (for example, 80° C.) higher than the melting temperature (for example, 60° C.) and lower than the curing temperature. This allows the resin material 90 to be placed (injected) into the magnet hole 322 in a pre-curing state (flowable molten state) without starting to cure the resin material 90.
  • the manufacturing method includes a magnet insertion process (step S6) in which a permanent magnet 62 is placed in the magnet hole 322 of the workpiece W on the support jig 120, as shown diagrammatically in FIG. 9.
  • the permanent magnet 62 may be inserted to a position where the lower end face 622 abuts against the surface of the support jig 120 without any gaps (i.e., a position where they make surface contact).
  • the magnet insertion process (step S6) is performed while maintaining the resin material 90 in the magnet hole 322 of the workpiece W in a molten state. Therefore, when the permanent magnet 62 is inserted into the molten resin material 90 that accumulates in the lower part of the magnet hole 322 of the workpiece W (the lower part with the surface of the support jig 120 on the lower side), the molten resin material 90 is pushed aside and rises by an amount corresponding to the volume of the permanent magnet 62.
  • the molten resin material 90 reaches the periphery of the permanent magnet 62 (it is pushed up by the permanent magnet 62 and reaches the periphery of the permanent magnet 62), and extends over the same extension range as the extension range of the resin material layer 72 as described above with reference to FIG. 3.
  • the resin material 90 has a relatively low melt viscosity as described above, so that it can easily and tightly extend around the permanent magnet 62 during the magnet insertion process. That is, the resin material 90 in the magnet hole 322 can easily wrap around the permanent magnet 62 while being pushed aside by the permanent magnet 62. This can increase the fixing strength of the resin material layer 72 formed by the resin material 90 (fixing strength related to the permanent magnet 62).
  • the resin material 90 preferably has a property that the curing reaction does not substantially proceed when in a molten state below the curing temperature.
  • the curing reaction does not substantially proceed may include, for example, a state in which the content of the curing reaction material is 10% or less.
  • the resin material 90 can maintain a relatively low melt viscosity as described above. Therefore, even in the magnet insertion process (step S6) performed after the resin injection process (step S5), the resin material 90 can maintain a relatively low melt viscosity as described above. This allows the resin material 90 to easily extend around the permanent magnet 62 without gaps during the magnet insertion process (step S6).
  • the amount V2 (ml) of resin material 90 injected into one magnet hole 322 may be less than the difference between the volume V0 (cm 3 ) of that one magnet hole 322 and the volume V1 (cm 3 ) of the permanent magnet 62 inserted into that one magnet hole 322 by a margin ⁇ (ml).
  • V2 V0 - V1 - ⁇ . This reduces the possibility that the molten resin material 90 pushed aside by the permanent magnet 62 will overflow from the magnet hole 322 during the magnet insertion process (step S6).
  • the allowance ⁇ is preferably adapted so that the resin material 90 does not reach the upper end surface 621 of the permanent magnet 62 during the magnet insertion process (step S6). This is because if a layer of resin material 90 is formed on the upper end surface 621 of the permanent magnet 62, a thermal stress problem will occur. That is, due to the difference in linear expansion coefficient between the permanent magnet 62 and the resin material 90 layer, thermal stress will be a problem due to the difference in axial expansion and contraction that occurs between the two when the temperature changes. Therefore, by adapting the allowance ⁇ , it is possible to reduce the thermal stress problem due to the difference in axial expansion and contraction between the resin material layer 72 and the permanent magnet 62.
  • the magnet insertion process (step S6) is performed while maintaining the resin material 90 in the magnet hole 322 of the workpiece W in a molten state.
  • heat may be applied to the resin material 90 in the magnet hole 322 of the workpiece W by the heating device 160 so that the molten state of the resin material 90 can be appropriately maintained.
  • the temperature of the resin material 90 may be heated to a hardening temperature or higher in a manner that does not impair the ease of inserting the permanent magnet 62 during the magnet insertion process (step S6). That is, the resin hardening process (step S7) described later may be started in a manner that overlaps with the magnet insertion process (step S6).
  • the temperature of the resin material 90 may be managed so that the temperature of the resin material 90 does not reach or exceed the hardening temperature (for example, so that it is maintained at a temperature significantly lower than the hardening temperature) until the magnet insertion process (step S6) is completed.
  • the heating device 160 which is one element of the manufacturing apparatus 100, is disposed radially inside and outside the rotor core 32 of the workpiece W.
  • the heating device 160 can heat the resin material 90 via the rotor core 32, so that the resin material 90 can be maintained in a molten state.
  • the heating device 160 may be, for example, an induction heating device.
  • Such a heating device 160 may also function in the resin injection process (step S5). That is, in the resin injection process (step S5), heat may be applied by the heating device 160 to the resin material 90 that is poured into the magnet hole 322. In this case, too, the heating device 160 can heat the resin material 90 via the rotor core 32, so that the molten state of the resin material 90 can be effectively maintained.
  • a preheating process may be separately performed to preheat the permanent magnet 62 to be inserted.
  • a magnet preheating process to preheat the permanent magnet 62 may be separately performed before the magnet insertion process (step S6).
  • heat can be applied directly to the resin material 90 by the permanent magnet 62 itself.
  • the magnet preheating process may preferably include heating the permanent magnet 62 to a temperature equal to or higher than the curing temperature of the resin material 90.
  • the resin material 90 rises to above the curing start temperature due to the heat of the permanent magnet 62 from the part that touches the permanent magnet 62.
  • the part of the resin material 90 that touches the permanent magnet 62 reaches above the curing start temperature and begins thermal curing.
  • the magnet insertion process is completed before the time it takes for the resin material 90 to cure (completely gel) (gel time or gelation time). Therefore, it is possible to achieve both ease of insertion of the permanent magnet 62 (ease of insertion work so that the permanent magnet 62 can be positioned at the desired position in the magnet hole 322) and positional stability of the positioned permanent magnet 62.
  • the positional stability of the permanent magnet 62 is achieved by making it difficult for the permanent magnet 62 to move due to an increase in the viscosity of the resin material 90 around the permanent magnet 62.
  • the resin material 90 is a thermoplastic resin material
  • the rotor core 32 and the like are heated (or preheated by the preheating process described above) to maintain the resin material 90 in a molten state during the magnet insertion process (step S6).
  • the temperature of the resin material 90 may be set relatively high during injection in the resin injection process (step S5). Even if the resin material 90 is a thermoplastic resin material, by appropriately setting the temperature of the resin material 90 during the magnet insertion process (step S6), it is possible to achieve both ease of insertion of the permanent magnet 62 (ease of positioning the permanent magnet 62 at the desired position within the magnet hole 322) and positional stability of the positioned permanent magnet 62.
  • the resin material 90 has a relatively low melt viscosity as described above, so that the resin material 90 is more likely to leak out from between the steel plates 3250 than when the resin material 90 has a relatively high melt viscosity.
  • the resin material 90 is not pressurized in the magnet hole 322, so that the possibility of the resin material 90 leaking out from between the steel plates 3250 can be reduced. That is, the magnet insertion process (step S6) is performed with the inside of the magnet hole 322 of the workpiece W open to atmospheric pressure. This significantly reduces the possibility of the resin material 90 leaking out from between the steel plates 3250 in the magnet insertion process (step S6).
  • the resin material 90 starts to harden when it comes into contact with the rotor core 32, so that the possibility of the resin material 90 leaking out from between the steel plates 3250 can be reduced.
  • a pressed state in which the rotor core 32 is pressed in the axial direction may be formed during the magnet insertion process (step S6).
  • the magnet insertion process (step S6) may be performed together with a pressing process in which the rotor core 32 is pressed in the axial direction.
  • the manufacturing apparatus 100 has a pressing tool 170 that applies an axial force to the rotor core 32.
  • the pressing tool 170 presses the workpiece W on the support tool 120 from above (see pressing force F80) and applies an axial force to the rotor core 32 (see axial force F82).
  • the pressing tool 170 may have a hole 172 that opens the upper part of the magnet hole 322. In this case, the permanent magnet 62 can be inserted while maintaining the pressing state of the pressing tool 170 against the rotor core 32.
  • Such a pressing tool 170 may also function in the resin injection process (step S5). That is, in the resin injection process (step S5), the resin material 90 may be placed in the magnet hole 322 under pressure from the pressing tool 170. In this case, it is possible to reduce the possibility that the resin material 90, which has a relatively low melt viscosity, will leak out from between the steel plates 3250 from the resin injection process (step S5) stage. In this case, the resin injection process (step S5) may be realized by utilizing the hole 172 of the pressing tool 170.
  • the manufacturing method includes a resin curing process (step S7) in which the resin material 90 injected into the magnet hole 322 is cured.
  • the resin curing process (step S7) includes heating the molten resin material 90 to a temperature equal to or higher than the curing temperature. Note that, if the resin material 90 is a thermoplastic resin material, the resin curing process (step S7) includes cooling the molten resin material 90 to a temperature equal to or lower than the curing temperature.
  • the resin curing process (step S7) may overlap with the magnet insertion process (step S6) in such a manner that the magnet insertion process (step S6) is completed before the resin curing process (step S7) is completed. That is, the resin curing process (step S7) may be performed in parallel with the magnet insertion process (step S6).
  • the temperature of the resin material 90 may be raised to a temperature equal to or higher than the curing temperature in the resin injection process (step S5). That is, part of the resin curing process (step S7) may be realized in the resin injection process (step S5).
  • thermosetting resin suitable as the resin material 90 when the thermosetting resin suitable as the resin material 90 is heated above the curing temperature, it gels and then undergoes a state change called complete curing.
  • Gelling refers to a state in which the viscosity of the resin rises sharply due to the crosslinking reaction, in other words, a transition to a semi-solid state.
  • Complete curing refers to a state in which the molecular chains after the crosslinking reaction are densified and stabilized. Note that. Generally, the gelation time is greater than the complete curing time.
  • the completion of the resin curing process (step S7) corresponds to the completion of gelation of the entire resin material 90 injected into the magnet hole 322.
  • step S7 when the resin curing process (step S7) is performed in parallel with the magnet insertion process (step S6), it is sufficient that the magnet insertion process (step S6) is completed by the time gelation is completed. In this case, the time required from the start of the magnet insertion process (step S6) to the completion of the resin curing process (step S7) can be shortened.
  • the resin curing process (step S7) may be realized by only these heat sources. In other words, the resin curing process (step S7) does not require the application of new heat energy (further heating).
  • the magnet preheating process (step S6A) is performed, as described above, the heat from the permanent magnets 62 initiates the curing reaction of the resin material 90. Therefore, even if the workpiece (the rotor core 32 with the permanent magnets 62 inserted therein) is moved for further heating, the permanent magnets 62 can be prevented from shifting in position due to the movement.
  • the heating device 160 which is one element of the manufacturing apparatus 100, is disposed radially inside and outside the rotor core 32 of the workpiece W, and can heat and harden the resin material 90 via the rotor core 32.
  • the heating device 160 is, for example, an induction heating device, but may also be realized by a heating furnace.
  • the resin curing process (step S7) is preferably performed while applying an axial force F92 to the rotor core 32 of the workpiece W, as shown in FIG. 11.
  • the manufacturing apparatus 100 has a pressing tool 170 that applies an axial force to the rotor core 32, as shown in FIG. 11, and the pressing tool 170 applies an axial force to the rotor core 32 by pressing the workpiece W on the support jig 120 from above (see pressing force F90) (see axial force F92).
  • the magnitude of the axial force F92 is preferably set based on the magnitude of the axial force that the rotor core 32 receives when assembling the rotor 30 using the rotor core 32 in the later step S9.
  • the axial force that the rotor core 32 receives when assembling the rotor 30 may correspond to, for example, the axial force (see force F10 in FIG. 1) generated by being clamped by the end plates 35A and 35B.
  • the magnitude of the axial force F92 may correspond to the design value or measured value of the magnitude of the axial force F10. Note that the design value does not necessarily have to be the value written on the design drawing, but is a concept that includes suitable values and target values obtained in the design through analysis, etc.
  • the magnitude of the axial force F92 generated in the workpiece W may be set based on the magnitude of the axial force F10 (hereinafter also referred to simply as "axial force F10 in the mounted state") that the rotor core 32 receives when assembling the rotor 30.
  • this manufacturing method includes a magnetization process (step S8) in which the permanent magnet 62 is magnetized.
  • the permanent magnet 62 when performing the magnet preheating process (step S6A), the permanent magnet 62 will be heated before the magnetization process (step S8), but this heating will not cause any substantial inconvenience (effect on the magnetization characteristics or the magnetic characteristics after magnetization).
  • the magnetization process (step S8) may be performed at an earlier stage (for example, before the magnet insertion process or the magnet preheating process).
  • this manufacturing method includes a step (step S9) of assembling the rotor 30 with the rotor core 32 after step S7.
  • the rotor core 32 is fixed (e.g., pressed in) to the rotor shaft 34, and end plates 35A, 35B are attached.
  • the rotor 30 assembled in this manner is then attached to a case (not shown) together with the stator 21, etc., to assemble the motor 1.
  • the permanent magnet 62 is inserted into the magnet hole 322 with the molten resin material 90 extending into the magnet hole 322. Therefore, during the magnet insertion process (step S6), the molten resin material 90 in the magnet hole 322 does not provide significant resistance to the insertion of the permanent magnet 62. This allows the permanent magnet 62 to be positioned at the desired position in the magnet hole 322. This effect is more pronounced when the resin material 90 has a relatively low melt viscosity. In this way, according to this manufacturing method, the permanent magnet 62 can be inserted into the desired position in the magnet hole 322 and fixed in place by the resin material 90.
  • a common heating device 160 and pressing tool 170 can be used in the magnet insertion process (step S6), or in the resin injection process (step S5) and magnet insertion process (step S6), and the resin hardening process (step S7). This allows for efficient manufacturing of the motor 1.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un rotor pour une machine électrique rotative, le procédé comprenant : une étape de préparation d'un noyau de rotor ayant des trous d'aimant axiaux et des aimants permanents pouvant être insérés dans les trous d'aimant ; une étape d'injection de résine pour injecter des matériaux de résine ayant différentes températures de fusion et températures de durcissement dans les trous d'aimant tandis que les matériaux de résine sont dans un état fondu ; une étape d'insertion d'aimant dans laquelle, après l'étape d'injection de résine, les aimants permanents sont insérés dans les trous d'aimant de telle sorte que les matériaux de résine fondue atteignent et entourent les aimants permanents ; et une étape de durcissement de résine pour durcir le matériau de résine, suivant l'étape d'insertion d'aimant.
PCT/JP2023/039035 2022-12-16 2023-10-30 Procédé de fabrication de rotor pour machine électrique rotative WO2024127833A1 (fr)

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JP2022201451A JP2024086362A (ja) 2022-12-16 2022-12-16 回転電機用ロータの製造方法
JP2022-201451 2022-12-16

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH1198735A (ja) * 1997-09-18 1999-04-09 Toyota Motor Corp 回転電機のロータ及び回転電機のロータの製造方法
JP2005080432A (ja) * 2003-09-01 2005-03-24 Mitsubishi Electric Corp モータ及びその製造方法
JP2016134967A (ja) * 2015-01-16 2016-07-25 アイシン・エィ・ダブリュ株式会社 樹脂充填方法及び樹脂充填装置
JP2019187118A (ja) * 2018-04-11 2019-10-24 トヨタ紡織株式会社 ロータコアの製造装置及び製造方法

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH1198735A (ja) * 1997-09-18 1999-04-09 Toyota Motor Corp 回転電機のロータ及び回転電機のロータの製造方法
JP2005080432A (ja) * 2003-09-01 2005-03-24 Mitsubishi Electric Corp モータ及びその製造方法
JP2016134967A (ja) * 2015-01-16 2016-07-25 アイシン・エィ・ダブリュ株式会社 樹脂充填方法及び樹脂充填装置
JP2019187118A (ja) * 2018-04-11 2019-10-24 トヨタ紡織株式会社 ロータコアの製造装置及び製造方法

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