JP5100614B2 - Magnet generator and manufacturing method thereof - Google Patents

Description

  The present invention relates to a magnet generator including a flywheel, a relucter provided outside the flywheel, and a signal generator provided radially outside the flywheel, and a method of manufacturing the same.

Conventionally, a flywheel formed in a bottomed cylindrical shape, a reluctator having a plurality of detected portions that are integrally formed on the outer peripheral surface of the cylindrical portion of the flywheel and project radially outward, and the outside of the flywheel There is known a magnet generator provided with a signal generator for detecting that it is opposed to each detected part (see, for example, Patent Document 1).
In this case, in order to be able to face the signal generator, each detected part of the reluctator is formed by cutting on the outer peripheral surface of the cylindrical portion of the flywheel in accordance with the position where the signal generator is attached. Yes.

JP 2007-244057 A

  However, in this case, since the reluctator is formed by cutting, there is a problem that it takes a long time to process the reluctator and the processing cost of the reluctor increases.

  An object of the present invention is to solve the above-described problems, and an object of the invention is to provide a magnet generator capable of reducing the processing time of the relaxor by reducing the processing time of the relaxor and The manufacturing method is provided.

  A magnet generator according to the present invention includes a flywheel formed in a bottomed cylindrical shape, a donut-shaped reluctator provided outside the flywheel, and a plurality of magnets provided on an inner peripheral surface of the flywheel. And a stator having a laminated iron core provided on the inner side of the flywheel and having an outer peripheral portion opposed to the magnet and a power generation coil provided on the laminated iron core, and a diameter from an outer peripheral side wall surface of the flywheel. A magnet generator that generates electric power by electromagnetic induction between the magnet and the power generation coil by rotating the rotor, and the reluctator is a bottom surface of the flywheel. A base portion provided on the outer peripheral side wall surface of the flywheel, a detected portion provided on a radially outer side, and the base portion and the detected portion. Was, the and a bent portion of the detected portion allowed facing the signal generator stator, wherein the signal Hatsudenko detects that facing the detected part.

  The magnet generator manufacturing method according to the present invention includes a sheet metal pressing process for forming the relaxor into a flat plate shape by sheet metal pressing, and a shearing process for forming the detected portion on the relaxor by shearing. A drawing step of forming the bent portion in the relaxor by drawing.

  According to the magnet generator according to the present invention, since the detected portion of the reluctator can be opposed to the signal generator by the bent portion, it is not necessary to form the reluctor by cutting, and the processing time of the reluctor is reduced. Thus, the processing cost of the reluctator can be reduced.

  Further, according to the method of manufacturing a magnet generator according to the present invention, the detected portion can be opposed to the signal generator by drawing, so that it is not necessary to form the reluctor by cutting, so that the reluctor can be processed. The required time can be reduced, and the processing cost of the reluctor can be reduced.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same or corresponding members and parts will be described with the same reference numerals.
Embodiment 1 FIG.
FIG. 1 is a plan view showing a magnet generator according to this embodiment, and FIG. 2 is a side sectional view showing the magnet generator of FIG.
The magnet generator according to this embodiment includes a rotor 1 and a stator 2 fixed to a fixing member (not shown) inside the rotor 1.
The rotor 1 has a flywheel 3 formed in a bottomed cylindrical shape, a reluctor 4 attached to the outside of the flywheel 3, and a plurality of magnets 5 fixed to the inner peripheral surface of the flywheel 3. is doing.
The magnets 5 are arranged at equal intervals in the circumferential direction of the flywheel 3.
At the center of the flywheel 3, a boss 3a to which a rotating shaft (not shown) is attached is formed.

The stator 2 has a laminated iron core 6 disposed inside the flywheel 3, an insulating member 7 attached to the laminated iron core 6, and a power generation coil 8 attached to the insulating member 7.
The laminated iron core 6 is formed in a hollow cylindrical shape, and the outer peripheral surface faces the magnet 5.
The insulating member 7 is made of a resin mold material. The insulating member 7 is not limited to a resin mold material, and may be composed of, for example, an epoxy powder.
The power generation coil 8 is insulated from the laminated iron core 6 by the insulating member 7.
The laminated iron core 6 includes a plurality of thin steel plates 9 stacked in the axial direction of the flywheel 3 and a pair of end plates 10 disposed at both ends of the thin steel plates 9 in the stacking direction.

A cylindrical protective ring 11 is fitted in close contact with each magnet 5 on the laminated iron core 6 side of each magnet 5.
A magnet positioning member 12 that fixes the positions of the magnet 5 and the protection ring 11 with respect to the flywheel 3 and fixes the magnet 5 and the protection ring 11 to the flywheel 3 is attached to the magnet 5 and the protection ring 11.
The magnet positioning member 12 is made of resin. The magnet positioning member 12 is not limited to resin, and may be formed of, for example, a molding material.

The magnet generator further includes a signal generator 13 fixed to a fixing member (not shown) on the outer side in the radial direction from the outer peripheral side wall surface of the flywheel 3.
The relaxer 4 extends over a base portion 4a that is in surface contact with the bottom surface of the flywheel 3, a plurality of detected portions 4b that are provided radially outward from the outer peripheral side wall surface of the flywheel 3, and a base portion 4a and a detected portion 4b. And a bent portion 4c formed integrally.
Each detected part 4b is arrange | positioned at equal intervals in the circumferential direction.
The detected portion 4b can be opposed to the signal generator 13 by the bent portion 4c.
The bent portion 4c includes an axial direction portion 14a bent in the axial direction from the base portion 4a, and a radial direction portion 14b bent outward in the radial direction from the distal end portion of the axial direction portion 14a.
The relaxor 4 is fixed to the flywheel 3 by fitting the axial direction portion 14 a to the outer periphery of the bottom surface portion of the flywheel 3.

Next, the operation of the magnet generator according to this embodiment will be described.
First, the flywheel 3 rotates in conjunction with the rotation of the rotating shaft.
When the flywheel 3 rotates, the reluctator 4 rotates in conjunction with it, and the detected part 4b of the reluctator 4 faces the signal generator 13 so that the magnetic flux passing through the signal generator 13 changes. A signal voltage is induced in a signal coil (not shown) of the signal generator 13.
The signal generator 13 measures the signal voltage to detect that the detected portion 4b of the reluctator 4 is opposed to the signal generator 13, and the rotation speed of the flywheel 3 and the rotation angle of the flywheel 3 Alternatively, the number of rotations of the rotation shaft connected to the flywheel 3 and the rotation angle of the rotation shaft are detected.

Next, a method for manufacturing the magnet generator according to this embodiment will be described.
First, a sheet metal pressing process is started, and the reluctator 4 is formed into a planar shape by sheet metal pressing.
Next, a shearing process is started, and the detected portion 4b is formed on the reluctator 4 by the shearing process.
Furthermore, the drawing process is started, and the bent portion 4c is formed in the reluctator 4 by drawing.
Finally, the reluctator 4 is fitted to the flywheel 3.

As described above, according to the magnet generator according to this embodiment, the reluctator 4 has the bent portion 4c so that the detected portion 4b can be opposed to the signal generator 13. Therefore, it is possible to reduce the processing cost of the relaxer 4 by reducing the time required for processing the relaxor 4.
Further, since the bent portion 4c is formed in the reluctator 4, the rigidity is enhanced compared to the flat plate-shaped reluctator 4, so that when vibration is transmitted from the rotary shaft to the reluctator 4, the reluctator is caused by the vibration. 4 is suppressed from being deformed.
As a result, it is possible to reduce errors in the rotational speed and rotational angle of the flywheel 3 detected by the signal generator 13.

  In addition, according to the method for manufacturing a magnet generator according to this embodiment, the detected portion 4b can be opposed to the signal generator 13 by drawing, so that it is not necessary to form the retractor 4 by cutting. By reducing the time required for processing the relaxor 4, the processing cost of the relaxer 4 can be reduced.

Embodiment 2. FIG.
FIG. 3 is a plan view showing the main part of the magnet generator according to this embodiment, and FIG. 4 is a cross-sectional view showing the main part of the magnet generator of FIG.
In the magnet generator according to this embodiment, the detected portions 4b of the reluctator 4 are formed not at regular intervals in the circumferential direction but at a part.
Two positioning holes 4d that determine a relative position with respect to the flywheel 3 by engaging with a convex portion (not shown) of the flywheel 3 are formed in the reluctator 4.
The engaging means is constituted by the convex portion of the flywheel 3 and the positioning hole 4 d of the reluctator 4.
By forming the detected portion 4b to be partially biased, the center of gravity of the reluctator 4 is shifted from the rotation axis, and a static unbalance occurs.
The convex part of the flywheel 3 and the positioning hole 4d of the reluctator 4 are formed at positions where this static unbalance is reduced.
In addition, when the flywheel 3 has a static unbalance, the convex part of the flywheel 3 and the positioning hole 4d of the retractor 4 are formed in consideration of the static unbalance of the flywheel 3.
In addition, when there is a static unbalance in the entire rotor 1, the convex portion of the flywheel 3 and the positioning hole 4 d of the reluctor 4 are formed in consideration of the entire static unbalance of the rotor 1.
Further, the engaging means may be composed of a positioning hole formed in the flywheel 3 and a convex portion formed in the reluctator 4 that engages with the positioning hole of the flywheel 3.
Even in this case, the positioning hole of the flywheel 3 and the convex part of the reluctator 4 are formed at positions where the static unbalance of the rotor 1 is reduced.

FIG. 5 is an enlarged cross-sectional view of a main part of the magnet generator shown in FIG.
Further, the magnet generator is formed with a stepped portion 3 b cut along the peripheral corner of the outer bottom surface of the flywheel 3.
The depth H in the axial direction of the stepped portion 3b is the length D of the axial portion 14a of the bent portion 4c, that is, from the surface of the base portion 4a on the flywheel 3 side to the surface of the radial portion 14b on the side opposite to the base portion 4a. It is smaller than the distance.
Thereby, the radial direction part 14b of the bending part 4c will be in the state pressed on the surface along the radial direction of the level | step-difference part 3b of the flywheel 3 with the elastic force by the bending deformation of the base 4a.
Other configurations are the same as those in the first embodiment.

  According to the magnet generator according to this embodiment, the flywheel 3 includes the stepped portion 3b cut out along the peripheral corner of the outer bottom surface, and the radial portion 14b of the bent portion 4c is the stepped portion of the flywheel 3. Since the surface along the radial direction 3b is pressed by the elastic force caused by the deformation of the base 4a, the radial portion 14b of the bent portion 4c vibrates slightly when the flywheel 3 rotates. And the error in the rotational speed and rotational angle of the flywheel 3 detected by the signal generator 13 can be reduced.

  The flywheel 3 is formed with a convex portion, and the reluctator 4 is formed with a positioning hole 4d that is engaged with the convex portion of the flywheel 3 to determine a relative position with respect to the flywheel 3. Since the convex portion 3 and the positioning hole 4d of the reluctator 4 are positions where the static unbalance of the rotor 1 is reduced, the number of steps for adjusting the static unbalance of the rotor 1 can be reduced.

  In each of the above-described embodiments, the magnet generator that fixes the reluctator 4 to the flywheel 3 by fitting the reluctor 4 to the flywheel 3 has been described. May be fixed to the flywheel 3 by welding to the flywheel 3, or may be fixed to the flywheel 3 by caulking using a rivet or the like.

It is a top view which shows the magnet generator which concerns on Embodiment 1 of this invention. It is a sectional side view which shows the magnet generator of FIG. It is a top view which shows the principal part of the magnet generator which concerns on Embodiment 2 of this invention. It is a sectional side view which shows the principal part of the magnet generator of FIG. It is the sectional side view to which the principal part of the magnet generator of FIG. 3 was expanded.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Rotor, 2 Stator, 3 Flywheel, 3a Boss part, 3b Step part, 4 Relucer, 4a Base part, 4b Detected part, 4c Bending part, 4d Positioning hole (engagement means), 5 magnet, 6 Laminated iron core , 7 Insulating member, 8 Power generation coil, 9 Thin steel plate, 10 End plate, 11 Protective ring, 12 Magnet positioning member, 13 Signal generator, 14a Axial direction part, 14b Radial direction part.

Claims (3)

A rotor having a flywheel formed in a bottomed cylindrical shape, a donut-shaped relaxer provided outside the flywheel, and a plurality of magnets provided on an inner peripheral surface of the flywheel;
A stator having a laminated core provided inside the flywheel and having an outer peripheral portion facing the magnet and a power generation coil provided in the laminated core;
With signal emission provided radially outward from the outer peripheral side wall surface of the flywheel,
In the magnet generator that generates power by the electromagnetic induction action of the magnet and the power generation coil by rotating the rotor,
The relaxor is provided across the base provided on the bottom surface of the flywheel, the detected part provided radially outside the outer peripheral side wall surface of the flywheel, and the base and the detected part. A bent portion that allows the detected portion to face the signal generator;
The signal emission is detected to face the detected part ,
The flywheel includes a stepped portion cut along a peripheral corner of the outer bottom surface,
The bent portion is composed of an axial portion bent in the axial direction from the base portion, and a radial portion bent outward in the radial direction from the distal end portion of the axial portion,
The depth of the stepped portion in the axial direction is smaller than the length of the bent portion in the axial direction, whereby the radial direction portion is bent on the surface along the radial direction of the stepped portion. A magnet generator characterized by being pressed by an elastic force due to deformation . The flywheel and the reluctator are engaged with each other to form engagement means for determining the relative position of each other.
The magnet generator according to claim 1, wherein the engaging means is located at a position where static unbalance of the rotor is reduced. It is a manufacturing method of the magnet generator according to claim 1 or 2 ,
A sheet metal pressing process for forming the reluctator into a flat plate shape by sheet metal pressing;
A shearing step of forming the detected portion on the reluctator by shearing; and
A magnet generator manufacturing method comprising: a drawing step of forming the bent portion in the relaxor by drawing.

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