阅读说明：本技术 旋转电机用转子的制造方法 (Method for manufacturing rotor for rotating electrical machine ) 是由 森田武 井手上薰树 渡边裕太 堂园健次 池邨将史 神谷敏彦 于 2020-01-28 设计创作，主要内容包括：本发明实现一种旋转电机用转子的制造方法,能减少相互作用于转子铁芯与筒状部的径向负载因轴向位置引起的偏差。旋转电机用转子(1)具备转子铁芯(2)和支承转子铁芯的铁芯支承部件(3),在铁芯支承部件具备形成为筒状的筒状部(11)以及相对于非旋转部件被支承为能够旋转并从径向(R)的内侧支承筒状部的支承部(12),使用形成为使嵌合面部(A2)的包含在径向观察下与连接区域(A1)重叠的重叠区域(A3)的特定区域(A4)的直径(D1)、小于嵌合面部(A2)的特定区域(A4)以外的区域亦即一般区域(A5)的直径(D2)的铁芯支承部件(3),在使转子铁芯膨胀的状态下,将铁芯支承部件相对于转子铁芯向径向的内侧插入,然后使转子铁芯(2)相对于筒状部(11)相对地收缩,使筒状部(11)的外周面(F1)与转子铁芯的内周面(F2)嵌合。(The invention provides a method for manufacturing a rotor for a rotating electrical machine, which can reduce the deviation of radial load which is acted on a rotor iron core and a cylindrical part mutually due to axial position. A rotor (1) for a rotating electrical machine is provided with a rotor core (2) and a core support member (3) for supporting the rotor core, wherein the core support member is provided with a cylindrical part (11) formed in a cylindrical shape and a support part (12) which is supported rotatably relative to a non-rotating member and supports the cylindrical part from the inside in the radial direction (R), the core support member (3) which is formed so that the diameter (D1) of a specific region (A4) including an overlapping region (A3) overlapping with a connection region (A1) in the radial direction of a fitting surface part (A2) is smaller than the diameter (D2) of a general region (A5) which is a region other than the specific region (A4) of the fitting surface part (A2) is used, the core support member is inserted radially inward relative to the rotor core in a state where the rotor core is expanded, and the rotor core (2) is relatively contracted relative to the cylindrical part (11), the outer peripheral surface (F1) of the cylindrical part (11) is fitted to the inner peripheral surface (F2) of the rotor core.)

1. A method of manufacturing a rotor for a rotating electrical machine, the rotor for a rotating electrical machine comprising a rotor core and a core support member supporting the rotor core, the core support member comprising a cylindrical portion formed in a cylindrical shape and a support portion supported rotatably with respect to a non-rotating member and supporting the cylindrical portion from a radially inner side,

the core support member is formed so that the support portion is connected to a connection region that is a region of the cylindrical portion in a part of the axial direction and extends from the connection region to the inside in the radial direction, a portion of the outer circumferential surface of the cylindrical portion that overlaps with the rotor core when viewed in the radial direction of the radial direction is a fitting surface portion, and a diameter of a specific region of the fitting surface portion that includes an overlapping region overlapping with the connection region when viewed in the radial direction is smaller than a diameter of a general region that is a region of the fitting surface portion other than the specific region,

inserting the core support member radially inward with respect to the rotor core in a state where the rotor core is expanded such that a diameter of an inner peripheral surface of the rotor core is larger than a diameter of the general region,

then, the rotor core is contracted relative to the cylindrical portion, and the outer circumferential surface of the cylindrical portion is fitted to the inner circumferential surface of the rotor core.

2. The manufacturing method of a rotor for a rotating electrical machine according to claim 1,

the diameter of the specific region is equal to or greater than the diameter of the inner circumferential surface of the rotor core, and the diameter of the general region is larger than the diameter of the inner circumferential surface of the rotor core in a state where the rotor core and the core support member are at the same temperature.

3. The manufacturing method of a rotor for a rotating electrical machine according to claim 1 or 2, wherein,

the length of the specific region in the axial direction is set to be longer than the length of the overlapping region in the axial direction.

4. The manufacturing method of a rotor for a rotating electrical machine according to claim 3,

the specific region is set to include the entire overlapping region.

5. The manufacturing method of a rotor for a rotating electrical machine according to claim 4,

the length of the specific region in the axial direction is set to a length obtained by adding lengths corresponding to the thicknesses of the cylindrical portions in the radial direction to both sides of the overlap region in the axial direction.

6. The manufacturing method of a rotor for a rotating electrical machine according to claim 4,

the length of the specific region in the axial direction is set to a length obtained by adding a length corresponding to the thickness of the cylindrical portion in the radial direction to one side in the axial direction with respect to the overlap region.

7. The method for manufacturing a rotor for a rotating electrical machine according to any one of claims 1 to 6, wherein,

an inclined surface is formed at an end portion of the specific region adjacent to the general region so that the diameter thereof gradually increases toward the general region.

8. The method for manufacturing a rotor for a rotating electrical machine according to any one of claims 1 to 7, wherein,

the rotor core is heated to a higher temperature than the core support member, whereby the rotor core is expanded.

Technical Field

The present invention relates to a method for manufacturing a rotor for a rotating electrical machine, the rotor including a rotor core and a core support member for supporting the rotor core.

Background

The following describes the background art. In the following description, the symbols or names in parentheses are those of the prior art documents. A conventional example of the rotor for a rotating electrical machine is described in japanese patent application laid-open No. 2013-095390 (patent document 1). In the rotor for a rotating electrical machine of patent document 1, the core support member (rotor support member 22) includes a cylindrical portion (rotor holding portion 25) formed in a cylindrical shape, and a support portion (radially extending portion 26) that supports the cylindrical portion from a radially inner side (R1). In such a rotor for a rotating electrical machine, the support portion is connected to a connection region, which is a region of the cylindrical portion in a part of the axial direction, and is formed to extend radially inward from the connection region. The rotor for the rotating electric machine is manufactured by fitting the inner peripheral surface of the rotor core to the outer peripheral surface of the cylindrical portion.

Patent document 1: japanese patent laid-open publication No. 2013-095390

As described above, when the inner peripheral surface of the rotor core is fitted to the outer peripheral surface of the cylindrical portion, the rotor core may be fastened to the cylindrical portion by, for example, shrink fitting. In the case of performing such a shrink fit, the rotor core is heated and expanded, and then the cylindrical portion is inserted radially inward of the rotor core, and then the rotor core is cooled and contracted to be fitted. When the rotor core is fitted to the cylindrical portion in this way, a radial load is applied to the rotor core and the cylindrical portion in an interaction manner. At this time, in a region of the cylindrical portion distant from the connection region with the support portion, the cylindrical portion is allowed to deform slightly radially inward, so that the radial load acting on the rotor core and the cylindrical portion mutually tends to be reduced. In contrast, in the region of the cylindrical portion near the connection region with the support portion, the cylindrical portion cannot be deformed radially inward due to the presence of the support portion, so that the radial load that interacts with the rotor core and the cylindrical portion is not reduced. Therefore, the radial load in the region close to the connection region with the support portion becomes relatively larger than in the other regions, and stress concentration tends to occur in this region. Since the rotor core is formed by laminating thin plates, if a large radial load is applied to a part of the axial region to cause stress concentration, there is a possibility that a problem such as deformation of a part of the thin plates may occur.

Disclosure of Invention

Therefore, it is desired to provide a method for manufacturing a rotor for a rotating electric machine, which can reduce the variation in the radial load that interacts with the rotor core and the cylindrical portion due to the axial position.

In view of the above circumstances, a method for manufacturing a rotor for a rotating electrical machine according to the present invention is a method for manufacturing a rotor for a rotating electrical machine including a rotor core and a core support member for supporting the rotor core, the core support member including a cylindrical portion formed in a cylindrical shape and a support portion supported rotatably with respect to a non-rotating member and supporting the cylindrical portion from a radially inner side, the method including the steps of: using the core support member, wherein the support portion is connected to a connection region that is a region of the cylindrical portion in a part of the axial direction, and is formed to extend from the connection region to the inside in the radial direction, a portion of the outer circumferential surface of the cylindrical portion that overlaps with the rotor core as viewed in the radial direction of the radial direction is a fitting surface portion, a specific region of the fitting surface portion that includes an overlapping region overlapping with the connection region as viewed in the radial direction has a diameter smaller than a diameter of a general region that is a region other than the specific region of the fitting surface portion, and the core support member is inserted into the rotor core in the radial direction with the rotor core expanded so that the diameter of the inner circumferential surface of the rotor core is larger than the diameter of the general region, then, the rotor core is contracted relative to the cylindrical portion, and the outer circumferential surface of the cylindrical portion is fitted to the inner circumferential surface of the rotor core.

According to the characteristic structure of the manufacturing method, the diameter of the specific region including the overlapping region overlapping with the connecting region of the support portion in the radial view, of the fitting surface portion of the cylindrical portion overlapping with the rotor core in the radial view, is smaller than the diameter of the general region, so that the radial load acting on the rotor core and the cylindrical portion in the specific region in interaction with each other can be reduced by an amount corresponding to the reduction in diameter as compared with the general region in a state where the outer peripheral surface of the cylindrical portion is fitted with the inner peripheral surface of the rotor core. Therefore, the difference between the radial load acting on the general region and the radial load acting on the specific region of the cylindrical portion can be reduced, and as a result, the variation in the radial load acting on the rotor core and the cylindrical portion due to the axial position can be reduced.

Drawings

Fig. 1 is a partial sectional view of a rotor for a rotating electrical machine.

Fig. 2 is a diagram showing a relationship among the diameter of the inner peripheral surface of the cylindrical portion, the diameter of the overlapping region, and the diameter of the specific region.

Fig. 3 is a view showing a manufacturing process of a rotor for a rotating electric machine.

Fig. 4 is a view showing a manufacturing process of a rotor for a rotating electric machine.

Fig. 5 is a partial sectional view of a rotor for a rotating electrical machine according to another embodiment.

Fig. 6 is a view showing the shape of an end portion of a specific region in another embodiment.

Fig. 7 is a view showing the shape of an end portion of a specific region in another embodiment.

Detailed Description

1. Detailed description of the preferred embodiments

Embodiments of a method for manufacturing a rotor for a rotating electrical machine will be described with reference to the drawings. As shown in fig. 1, a rotor 1 for a rotating electrical machine includes a rotor core 2 and a core support member 3 that supports the rotor core 2. In the following description, unless otherwise specified and described, the "axial direction L", "radial direction R", and "circumferential direction" are defined with reference to the axial center of the rotor 1 for the rotating electric machine. Further, "axial first side L1" indicates a side in the axial direction L (left side in fig. 1), and "axial second side L2" indicates a side opposite to the axial first side L1 (right side in fig. 1). Further, "radially inner side R1" represents a direction toward the inner side of the radial direction R, and "radially outer side R2" represents a direction toward the outer side of the radial direction R.

The rotor core 2 is configured by laminating a plurality of electromagnetic steel plates 6 formed in an annular plate shape in the axial direction L. In the present embodiment, end plates 7 are disposed at both ends of the rotor core 2 in the axial direction L.

The core support member 3 includes a cylindrical portion 11 formed in a cylindrical shape, and a support portion 12 supported rotatably with respect to a housing 13 that houses the rotor 1 for the rotating electrical machine and supporting the cylindrical portion 11 from inside in the radial direction R. In the present embodiment, the cylindrical portion 11 is formed integrally with the support portion 12. The outer peripheral surface F1 of the cylindrical portion 11 is fitted to the inner peripheral surface F2 of the rotor core 2. The support portion 12 is connected to a connection region a1, which is a partial region in the axial direction L of the cylindrical portion 11, and is formed to extend from the connection region a1 inward in the radial direction R.

The cylindrical portion 11 includes: a connecting portion 16 having a connecting region a1, a first extending portion 17 formed to extend from the connecting portion 16 toward the axial first side L1, and a second extending portion 18 formed to extend from the connecting portion 16 toward the axial second side L2. The first extension 17 extends from an end of the axial first side L1 of the rotor core 2 to the axial first side L1, and the second extension 18 extends from an end of the axial second side L2 of the rotor core 2 to the axial second side L2.

The core support member 3 further includes a first protruding portion 21 formed to protrude from an end of the first extension portion 17 on the first axial side L1 toward the outer radial side R2. The core support member 3 further includes a caulking portion 22 provided at an end portion of the second axial side L2 of the second extending portion 18. The caulking portion 22 is formed by bending an end portion of the second extending portion 18 on the axial second side L2 to the radial outer side R2 after the rotor core 2 is fitted to the cylindrical portion 11 from the axial second side L2. The movement of the rotor core 2 in the axial direction L with respect to the core support member 3 is restricted by the first protruding portion 21 and the caulking portion 22.

The support portion 12 includes: the ring-shaped support member includes a ring-shaped ring portion 26 extending in the radial direction R, a first supported portion 27 projecting from an end of a radially inner side R1 of the ring portion 26 toward the axial first side L1, and a second supported portion 28 projecting from an end of a radially inner side R1 of the ring portion 26 toward the axial second side L2. In the present embodiment, the rotor 1 for the rotating electrical machine is housed in the case 13, the first bearing 29 is disposed between the first supported portion 27 and the case 13, and the second bearing 30 is disposed between the second supported portion 28 and the case 13. The support portion 12 is rotatably supported by the housing 13 via a first bearing 29 and a second bearing 30. In the present embodiment, the housing 13 corresponds to a non-rotating member.

The annular portion 26 has a wide portion 26A at an end portion of the radially outer side R2, the width of which in the axial direction L is wider as going to the radially outer side R2, and the end portion of the radially outer side R2 of the wide portion 26A is connected to the connecting portion 16 of the cylindrical portion 11. In the present embodiment, the inner peripheral surface of the cylindrical portion 11 is formed parallel to the axial direction L, and the boundary between the portion where the width of the axial direction L increases as it goes to the radial outer side R2 and the portion parallel to the axial direction L is the boundary between the cylindrical portion 11 and the support portion 12.

The rotor 1 for a rotating electrical machine is characterized by the shape of the outer peripheral surface F1 of the cylindrical portion 11 fitted to the inner peripheral surface F2 of the rotor core 2. Here, a portion of the outer peripheral surface F1 of the cylindrical portion 11 that overlaps the rotor core 2 when viewed in the radial direction R is defined as a fitting surface portion a 2. In the present embodiment, a portion of the outer peripheral surface F1 of the cylindrical portion 11 that overlaps with the plurality of electromagnetic steel plates 6 included in the rotor core 2 when viewed in the radial direction is defined as a fitting surface portion a2, and portions that overlap with the pair of end plates 7 disposed at both ends of the rotor core 2 in the axial direction L when viewed in the radial direction are not included in the fitting surface portion a 2. However, a portion of the outer peripheral surface F1 of the cylindrical portion 11 that overlaps with the plurality of electromagnetic steel plates 6 of the rotor core 2 in the radial direction may be the fitting surface portion a2, as well as a portion that overlaps with at least one of the pair of end plates 7 in the radial direction.

Further, the diameter D1 of the specific region a4 including the overlapping region A3 of the fitting surface portion a2 that overlaps with the connecting region a1 in the radial view is smaller than the diameter D2 of the general region a5 that is a region other than the specific region a4 of the fitting surface portion a2 with respect to the outer peripheral surface F1 of the cylindrical portion 11. More specifically, in a state where the rotor core 2 and the core support member 3 are at the same temperature, the diameter D1 of the specific region a4 is equal to or greater than the diameter D3 of the inner circumferential surface F2 of the rotor core 2, and the diameter D2 of the general region a5 is larger than the diameter D3 of the inner circumferential surface F2 of the rotor core 2. Here, the difference between the diameter D1 of the specific region a4 and the diameter D2 of the general region a5 is set to be extremely small. In the present embodiment, the difference between the diameter D1 of the specific region a4 and the diameter D2 of the general region a5 is set to several tens of micrometers, specifically, 20 to 30 micrometers. The diameter D1 of the specific region a4 when compared with other diameters is set to the diameter D1 of the portion of the specific region a4 other than the end 31 (inclined surface F3) described later. In the present embodiment, the diameter D1 of the specific region a4 is smaller than the diameter D2 of the general region a5 over the entire circumferential direction of the specific region a 4.

In the present embodiment, as shown in fig. 2, in a state where the rotor core 2 and the core support member 3 are at the same temperature, both the diameter D1 of the specific region a4 and the diameter D2 of the general region a5 of the fitting surface portion a2 are larger than the diameter D3 of the inner circumferential surface F2 of the rotor core 2. In addition, in the case of setting such dimensions, tolerances are set for the diameter D1 of the specific region a4, the diameter D2 of the general region a5, and the diameter D3 of the inner peripheral surface F2, respectively, in consideration of manufacturing errors. Here, a first tolerance ± α is set for the diameter D1 of the specific region a4 and the diameter D2 of the general region a 5. In addition, a second tolerance ± β is set for the diameter D3 of the inner circumferential surface F2. Here, the tolerance of the diameter D1 of the specific region a4 and the tolerance of the diameter D2 of the general region a5 are set to the same value, but the tolerance of the diameter D1 of the specific region a4 and the tolerance of the diameter D2 of the general region a5 may be set to different values.

In the present embodiment, as a preferable example, the diameter D1 of the specific region a4 and the diameter D2 of the general region a5 of the outer peripheral surface F1 and the diameter D3 of the inner peripheral surface F2 are set as follows. That is, the designed value of the diameter D1 of the specific region a4 is set as the first design value, the designed value of the diameter D2 of the general region a5 is set as the second design value, and the designed value of the diameter D3 of the inner peripheral surface F2 is set as the third design value. The value obtained by subtracting the first tolerance α from the first design value (diameter D1) is set to be equal to the value obtained by adding the second tolerance β to the third design value (diameter D3). The value obtained by adding the second tolerance β to the third design value (diameter D3) is set to be smaller than the value obtained by subtracting the first tolerance α from the second design value (diameter D2).

In addition, with regard to the setting of the specific region a4, the length in the axial direction L of the specific region a4 is set to be longer than the length in the axial direction L of the overlap region A3. The specific region a4 is set to include the entire overlap region A3. Specifically, the range of the specific region a4 in the axial direction L is set to include the entire range of the overlap region A3 in the axial direction L. In this example, the circumferential range of the specific region a4 is set to include the entire circumferential range of the overlap region A3. In the present embodiment, a range sandwiched by two imaginary lines each inclined by a set angle θ so as to face outward in the axial direction L toward the radial outer side R2, and two intersections of the two imaginary lines with the outer peripheral surface F1 of the cylindrical portion 11, of the end portions of the radial outer side R2 of the wide portion 26A in the axial direction L, is set as the specific region a 4. In the present embodiment, the set angle θ is set to 45 degrees. More specifically, the end portion of the first axial side L1 of the specific region a4 is set to be the intersection point of an imaginary line inclined by the set angle θ from the end portion of the first axial side L1, which is the end portion of the radially outer side R2 of the wide portion 26A, and the outer peripheral surface F1 of the cylindrical portion 11 toward the first axial side L1 as it goes toward the radially outer side R2. On the other hand, the end of the second side L2 in the axial direction of the specific region a4 is set to the end of the second side L2 in the axial direction of the outer peripheral surface F1 of the cylindrical portion 11. This is because there is no intersection point between an imaginary line inclined by the set angle θ from the end of the radial outer side R2 of the wide width portion 26A, that is, the end of the axial second side L2, and the outer peripheral surface F1 of the cylindrical portion 11 toward the radial outer side R2 and toward the axial second side L2.

As described above, in the present embodiment, since the set angle θ is set to 45 degrees, the length D4 of the specific region a4 in the axial direction L is set to a length obtained by adding a length corresponding to the thickness D5 of the cylindrical portion 11 in the radial direction R to both sides of the overlap region A3 in the axial direction L. In the present embodiment, since the length of the cylindrical portion 11 on the second side L2 in the axial direction from the overlap region A3 is shorter than the length D5, the specific region a4 is shorter than the length obtained by adding a length corresponding to the thickness D5 in the radial direction R of the cylindrical portion 11 to both sides in the axial direction L with respect to the overlap region A3. In this way, when the range of the length obtained by adding the length corresponding to the thickness D5 in the radial direction R of the cylindrical portion 11 to both sides in the axial direction L of the overlap region A3 reaches the end portion in the axial direction L of the cylindrical portion 11 at least on one side in the axial direction L, the end portion in the axial direction L is defined as the specific region a 4. In the present embodiment, the thickness in the radial direction R of the cylindrical portion 11 is used at the end of the first axial side L1 of the wide portion 26A in the axial direction L, as the thickness in the radial direction R of the cylindrical portion 11.

In the present embodiment, the inclined surface F3 is formed at the end of the specific region a4 adjacent to the general region a5 so that the diameter D1 gradually increases toward the general region a 5. In the present embodiment, the inclined surface F3 is formed at the end 31 of the first side L1 in the axial direction of the specific region a 4. In the illustrated example, the inclined surface F3 has a cross-sectional shape along the axial direction L that is formed in a linear shape that is inclined from the end of the axial second side L2 of the general region a5 toward the radial inner side R1 toward the axial second side L2.

Next, a method of manufacturing the rotor 1 for the rotating electric machine will be described. In the present embodiment, when manufacturing the rotor 1 for the rotating electric machine, a first step of inserting the core support member 3 into the rotor core 2 along the radially inner side R1 in a state where the rotor core 2 is expanded is performed; and a second step of, after the first step, contracting the rotor core 2 relative to the cylindrical portion 11 and fitting the outer peripheral surface F1 of the cylindrical portion 11 to the inner peripheral surface F2 of the rotor core 2. In the present embodiment, the rotor core 2 is heated to a higher temperature than the core support member 3 to expand the rotor core 2. That is, the outer peripheral surface F1 of the cylindrical portion 11 is fitted to the inner peripheral surface F2 of the rotor core 2 by so-called shrink fitting.

As shown in fig. 3, the first step is a step of inserting the core support member 3 into the rotor core 2 along the radially inner side R1 in a state where the rotor core 2 is expanded such that the diameter D3 of the inner peripheral surface F2 of the rotor core 2 is larger than the diameter D2 of the general region a5 of the cylindrical portion 11. In the first step of the present embodiment, the rotor core 2 is heated to a higher temperature than the core support member 3 and expanded so that the diameter D3 of the inner peripheral surface F2 of the rotor core 2 is larger than the diameter D2 of the general region a5 of the cylindrical portion 11. Then, in the state where the rotor core 2 is expanded in this way, the cylindrical portion 11 of the core support member 3 is inserted radially inward R1 with respect to the inner circumferential surface F2 of the rotor core 2. In the present embodiment, the cylindrical portion 11 is inserted into the rotor core 2 from the axial first side L1, and the end of the rotor core 2 on the axial first side L1 is brought into contact with the first protruding portion 21. Then, the second process is performed. In this way, in a state where the cylindrical portion 11 is inserted radially inward R1 with respect to the inner circumferential surface F2 of the rotor core 2, the fitting surface portion a2 of the outer circumferential surface F1 of the cylindrical portion 11 overlaps the rotor core 2 in a radial view, and the connection region a1 overlaps the overlapping region A3 in the radial view.

As shown in fig. 4, the second step is a step of relatively contracting the rotor core 2 with respect to the cylindrical portion 11 of the core support member 3, and fitting the outer circumferential surface F1 of the cylindrical portion 11 with the inner circumferential surface F2 of the rotor core 2. In the second step of the present embodiment, the rotor core 2 heated and expanded in the first step is cooled to contract. When the rotor core 2 is contracted in a state where the outer peripheral surface F1 of the cylindrical portion 11 and the inner peripheral surface F2 of the rotor core 2 face each other in the radial direction R, the outer peripheral surface F1 of the cylindrical portion 11 is fitted to the inner peripheral surface F2 of the rotor core 2. Here, the outer peripheral surface F1 of the cylindrical portion 11 and the inner peripheral surface F2 of the rotor core 2 are fitted to each other with interference. That is, assuming that the cylindrical portion 11 is not located radially inward R1 of the rotor core 2, the rotor core 2 is relatively contracted with respect to the cylindrical portion 11 such that the diameter D3 of the inner circumferential surface F2 of the rotor core 2 is the same as the diameter D1 of the specific region a4 or smaller than the diameter D1 of the specific region a 4. Thereby, the outer peripheral surface F1 of the cylindrical portion 11 and the inner peripheral surface F2 of the rotor core 2 are fitted to each other with interference. In the present embodiment, after the second step, as shown in fig. 4, the end portion of the second extending portion 18 on the second side L2 in the axial direction is bent outward in the radial direction R2 to form the caulking portion 22. This restricts the rotor core 2 from moving in the axial direction L relative to the core support member 3.

By fitting the rotor core 2 in this manner, the diameter D3 of the inner circumferential surface F2 of the rotor core 2 is reduced so as to be equal to the diameter D1 of the specific region a4 or smaller than the diameter D1 of the specific region a4 and smaller than the diameter D2 of the general region a 5. Thereby, a load in the radial direction R interacts with the rotor core 2 and the cylindrical portion 11. At this time, in the region of the cylindrical portion 11 apart from the connection region a1 with the support portion 12, the cylindrical portion 11 is allowed to deform slightly toward the radially inner side R1, so that the radial load acting on the rotor core 2 and the cylindrical portion 11 mutually tends to be reduced. In contrast, in the region of cylindrical portion 11 close to connection region a1 with support portion 12, cylindrical portion 11 cannot be deformed radially inward R1 due to the presence of support portion 12.

However, according to the configuration of the present embodiment, since the diameter D1 of the specific region a4 is smaller than the diameter D2 of the general region a5, the radial load that interacts with the rotor core 2 and the cylindrical portion 11 in the specific region a4 can be reduced by an amount corresponding to the diameter reduction as compared with the general region a 5. Therefore, the difference between the radial load acting on the general region a5 and the radial load acting on the specific region a4 of the cylindrical portion 11 can be reduced, and as a result, the variation in the radial load acting on the rotor core 2 and the cylindrical portion 11 due to the axial position can be reduced. Note that, in fig. 1, although it is illustrated that a gap is formed between the inner peripheral surface F2 of the rotor core 2 and the specific region a4 for easy understanding, actually, as illustrated in fig. 4, the inner peripheral surface F2 of the rotor core 2 is in contact with the specific region a4, and no gap is formed.

2. Other embodiments

Next, another embodiment of the method for manufacturing a rotor for a rotating electric machine will be described.

(1) In the above embodiment, the description has been given taking as an example a configuration in which the connection region a1 between the support portion 12 and the cylindrical portion 11 is set at a position offset to one side in the axial direction L with respect to the center portion in the axial direction L of the cylindrical portion 11. However, the connection structure of the support portion 12 and the cylindrical portion 11 is not limited thereto. For example, as shown in fig. 5, a connection region a1 between the support portion 12 and the cylindrical portion 11 may be provided at the center of the cylindrical portion 11 in the axial direction L. In the example shown in fig. 5, the specific region a4 ensures a range from the end of the overlap region A3 in the axial direction L to a length corresponding to the thickness D5 in the radial direction R of the cylindrical portion 11 on both sides of the overlap region A3 in the axial direction L.

(2) In the above embodiment, the description has been given of the example in which the length D4 in the axial direction L of the specific region a4 is set to a length obtained by adding lengths corresponding to the thickness D5 in the radial direction R of the cylindrical portion 11 to both sides in the axial direction L of the overlap region A3, but the setting of the length D4 in the axial direction L of the specific region a4 is not limited to this. For example, the length D4 in the axial direction L of the specific region a4 may be set to a length obtained by adding a length shorter than the thickness of the cylindrical portion 11 in the radial direction R or a length longer than the thickness of the cylindrical portion 11 in the radial direction R to both sides in the axial direction L of the overlap region A3. The length D4 in the axial direction L of the specific region a4 may be set to the same length as the length D3 in the axial direction L of the overlap region A3 or shorter than the length D3 in the axial direction L of the overlap region A3. The range in the axial direction L of the specific region a4 may be set to a range extending only to one side in the axial direction L with respect to the overlap region A3. The range of the specific region a4 in the axial direction L may be set to a range including only a part of the range of the overlap region A3 in the axial direction L.

(3) In the above embodiment, the description has been given taking as an example a configuration in which the inclined surface F3 having a linear cross-sectional shape along the axial direction L is formed at the end 31 of the specific region a4 adjacent to the general region a 5. However, the shape of the end 31 of the specific area a4 is not limited thereto. For example, as shown in fig. 6, the end 31 of the specific region a4 may have an inclined surface F3 (S-shaped inclined surface) that is curved so that the inclination gradually increases toward the radial outer side R2 as it goes toward the general region a5 side and then gradually decreases. Alternatively, as shown in fig. 7, the end 31 of the specific region a4 may be formed with a stepped portion F4 without forming the inclined surface F3.

(4) In the above embodiment, the rotor core 2 is described as an example in which a plurality of electromagnetic steel plates 6 formed in an annular plate shape are stacked in the axial direction L. However, the structure of the rotor core 2 is not limited thereto. For example, the rotor core 2 may be formed by a sintered core or a pressed powder core using magnetic powder.

(5) In the above embodiment, the diameter D1 of the specific region a4 is made smaller than the diameter D2 of the general region a5 over the entire circumferential region of the specific region a 4. However, the diameter D1 of the specific area a4 is not limited thereto. For example, the specific region a4 may include an equal-diameter region having a diameter D1 that is the same as the diameter D2 of the general region a5, and a small-diameter region having a diameter D1 that is smaller than the diameter of the general region a 5. For example, when the specific region a4 includes an equal-diameter region and a small-diameter region, the equal-diameter region and the small-diameter region may be alternately arranged in the circumferential direction.

(6) The structure disclosed in each of the above embodiments can be applied in combination with the structure disclosed in the other embodiments as long as no contradiction occurs. The embodiments disclosed in the present specification are merely examples in all respects. Therefore, various changes can be made as appropriate without departing from the spirit and scope of the present invention.

3. Summary of the above embodiments

The following describes an outline of the above-described method for manufacturing a rotor for a rotating electrical machine.

A method for manufacturing a rotor (1) for a rotating electrical machine, the rotor (1) for a rotating electrical machine comprising a rotor core (2) and a core support member (3) for supporting the rotor core (2), the core support member (3) comprising a cylindrical portion (11) formed in a cylindrical shape and a support portion (12) supported rotatably with respect to a non-rotating member (13) and supporting the cylindrical portion (11) from the inside in a radial direction (R), the core support member (3) being formed such that the support portion (12) is connected to a connection region (A1) which is a region of a part of an axial direction (L) of the cylindrical portion (11) and is formed to extend from the connection region (A1) to the inside in the radial direction (R), and a portion of an outer peripheral surface (F1) of the cylindrical portion (11) which overlaps the rotor core (2) when viewed in the radial direction (R) is fitted in the rotor core support portion A fitting surface portion (A2) in which the diameter (D1) of a specific region (A4) of the fitting surface portion (A2) including an overlapping region (A3) overlapping the connecting region (A1) in the radial view is smaller than the diameter (D2) of a general region (A5) of the fitting surface portion (A2) other than the specific region (A4), in a state where the rotor core (2) is expanded such that the diameter (D3) of the inner peripheral surface (F2) of the rotor core (2) is larger than the diameter (D2) of the general region (A5), the core support member (3) is inserted into the rotor core (2) in the radial direction (R), then, the rotor core (2) is contracted relatively to the cylindrical part (11), the outer peripheral surface (F1) of the cylindrical portion (11) is fitted to the inner peripheral surface (F2) of the rotor core (2).

According to this configuration, in the fitting surface portion (a2) of the cylindrical portion (11) that overlaps the rotor core (2) when viewed in the radial direction, the diameter (D1) of the specific region (a4) including the overlapping region (A3) that overlaps the connection region (a1) of the support portion (12) when viewed in the radial direction is smaller than the diameter (D2) of the general region (a5), so in a state in which the outer peripheral surface (F1) of the cylindrical portion (11) is fitted to the inner peripheral surface (F2) of the rotor core (2), the radial load that mutually acts on the rotor core (2) and the cylindrical portion (11) in the specific region (a4) can be reduced by an amount corresponding to a reduction in diameter as compared to the general region (a 5). Therefore, the difference between the radial load acting on the general region (A5) and the radial load acting on the specific region (A4) of the cylindrical part (11) can be reduced, and as a result, the variation in the radial load acting on the rotor core (2) and the cylindrical part (11) due to the axial position can be reduced.

Here, preferably, in a state where the rotor core (2) and the core support member (3) are at the same temperature, the diameter (D1) of the specific region (a4) is equal to or greater than the diameter (D3) of the inner circumferential surface (F2) of the rotor core (2), and the diameter (D2) of the general region (a5) is larger than the diameter (D3) of the inner circumferential surface (F2) of the rotor core (2).

According to this configuration, in a state in which the outer peripheral surface (F1) of the cylindrical portion (11) is fitted to the inner peripheral surface (F2) of the rotor core (2), the entire fitting surface portion (A2) of the outer peripheral surface (F1) of the cylindrical portion (11) including the specific region (A4) and the general region (A5) can be brought into contact with the inner peripheral surface (F2) of the rotor core (2). Therefore, as described above, it is possible to reduce the variation in the radial load that interacts with the rotor core (2) and the cylindrical portion (11) due to the axial position and to appropriately secure the fastening force between the cylindrical portion (11) of the core support member (3) and the rotor core (2).

Preferably, the length (D4) in the axial direction (L) of the specific region (a4) is set to be longer than the length (A3) in the axial direction (L) of the overlapping region (A3).

According to this configuration, the range in the axial direction (L) that is larger than the overlap region (A3) is set as the specific region (a 4). Thus, the specific region (A4) is easily included in a region where the radial load that is caused by the presence of the support portion (12) to act on the rotor core (2) and the cylindrical portion (11) mutually tends to increase. Therefore, the radial load acting on the rotor core (2) and the cylindrical part (11) mutually can be further reduced from the deviation caused by the axial position.

Preferably, the specific region (a4) is set to include the entire overlapping region (A3).

According to this configuration, the range of the specific region (a4) is set so as to include the entire overlapping region (A3) overlapping the connection region (a1) when viewed in the radial direction. Thus, the overlapping region (A3) in which the radial load that interacts with the rotor core (2) and the cylindrical section (11) due to the presence of the support section (12) is likely to increase can be included in the specific region (A4). Therefore, the radial load acting on the rotor core (2) and the cylindrical part (11) mutually can be reduced properly due to the deviation caused by the axial position.

Preferably, the length (D4) in the axial direction (L) of the specific region (a4) is set to a length obtained by adding a length corresponding to the thickness (D5) in the radial direction (R) of the cylindrical portion (11) to both sides in the axial direction (L) with respect to the overlap region (A3).

According to this configuration, in addition to the overlapping region (A3) that overlaps the connecting region (a1) when viewed in the radial direction, regions that are affected by the presence of the support portion (12) on both sides in the axial direction (L) are defined as specific regions (a 4). Thus, the specific region (A4) can be appropriately included in a region in which the radial load that is caused by the presence of the support portion (12) to act on the rotor core (2) and the cylindrical portion (11) in an interaction manner tends to increase. Therefore, the radial load acting on the rotor core (2) and the cylindrical part (11) mutually can be further reduced properly due to the deviation caused by the axial position.

Preferably, the length (D4) in the axial direction (L) of the specific region (a4) is set to a length obtained by adding a length corresponding to the thickness (D5) in the radial direction (R) of the cylindrical portion (11) to the overlap region (A3) on one side in the axial direction (L).

According to this configuration, in addition to the overlapping region (A3) that overlaps the connection region (a1) when viewed in the radial direction, a region that is affected by the presence of the support portion (12) on one side in the axial direction (L) is set as the specific region (a 4). Thus, a region in which the radial load acting on the rotor core (2) and the cylindrical part (11) in the axial direction (L) is likely to increase due to the presence of the support part (12) can be included in the specific region (A4) on the side of the overlap region (A3). In addition, the degree of freedom of the connection position of the support section (12) with respect to the cylindrical section (11) such as the connection of the support section (12) with the cylindrical section (11) can be increased such that the width in the axial direction (L) of the region of the specific region (A4) that is present on the opposite side of the overlap region (A3) from the axial direction (L) is smaller than the length corresponding to the thickness (D5). Therefore, the variation of the radial load acting on the rotor core (2) and the cylindrical part (11) in interaction with each other due to the axial position can be reduced appropriately, and the degree of freedom of the connecting position of the support part (12) with respect to the cylindrical part (11) can be improved.

Preferably, an inclined surface (F3) is formed at an end (31) of the specific region (a4) adjacent to the general region (a5) such that the diameter (D1) gradually increases toward the general region (a 5).

According to this configuration, it is possible to reduce the possibility that a region where the radial load acting on the rotor core (2) and the cylindrical portion (11) is large is generated at the boundary portion between the specific region (A4) and the general region (A5). Therefore, the radial load acting on the rotor core (2) and the cylindrical part (11) mutually can be further reduced properly due to the deviation caused by the axial position.

Preferably, the rotor core (2) is heated to a higher temperature than the core support member (3) to expand the rotor core (2).

According to this configuration, the rotor core (2) can be expanded by thermal expansion so that the diameter (D3) of the inner peripheral surface (F2) of the rotor core (2) is larger than the diameter (D2) of the general region (A5). Then, the core support member (3) can be inserted radially inward of the rotor core (2) and the rotor core (2) is cooled, so that the rotor core (2) contracts relative to the cylindrical portion (11) and the outer peripheral surface (F1) of the cylindrical portion (11) can be fitted to the inner peripheral surface (F2) of the rotor core (2). That is, according to this configuration, the cylindrical portion (11) and the rotor core (2) can be appropriately fitted by so-called shrink fitting.

Possibility of industrial utilization

The technique of the present invention can be applied to a method for manufacturing a rotor for a rotating electrical machine including a rotor core and a core support member that supports the rotor core.

Description of reference numerals

1: rotor for rotating electrical machine

2: rotor core

3: iron core supporting component

11: cylindrical part

12: support part

13: casing (non-rotating parts)

A1: connection area

A2: fitting face

A3: overlapping area

A4: specific region

A5: general area

D1: diameter of the specific region

D2: diameter of general area

D3: diameter of inner peripheral surface

D4: length of

D5: thickness of

F1: peripheral surface

F2: inner peripheral surface

F3: inclined plane

L: axial direction

R: and radial direction.