JPS5932982B2 - Rotor of magnet generator and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a highly accurate structure and manufacturing method for a rotor of a magnet generator.

First, the structure of a conventional magnet generator will be explained with reference to FIG. 1'.

The boss 1 integrally includes a cylindrical portion 2 and a flywheel ring 3, and is formed by cold forging or the like.

4 is a magnetic pole integrally formed with a magnetic pole piece 41 extending in the axial direction and a bottom part 42 formed perpendicular to the magnetic pole piece in cross section, and is formed from a mild steel wire usually used for rivets in the riveted holes bored in each other. It is fixed by caulking with studs 5.

The six-pole star magnet 6 is closely attached to the inside of the magnetic pole piece 41, and in this state is integrally die-cast from a non-magnetic metal 7 such as aluminum.

In such a structure, integrally cold-forming the boss with a press requires press equipment with a large capacity as the flywheel ring becomes larger. For example, if the outer diameter is about φ125, a capacity of 1500 tons is required, which increases the cost. It has become very expensive.

Furthermore, the presence of this large flywheel ring during die-casting operations complicates the structure of the mold, resulting in poor molding workability.

An object of the present invention is to provide a method for manufacturing a rotor for a magnet generator that is mechanically stable, easy to assemble, and inexpensive.

A feature of the present invention is that four annular gaps and grooves are provided along the entire circumference between the outer circumference of the boss and the inner circumference of a separate flywheel ring, and a ring-shaped coupling member is inserted between the gaps and grooves. The point is that the bonding force is obtained by shearing force and tension force.

Embodiments of the present invention will be described below with reference to FIG. 2 and subsequent figures.

A magnetic pole plate 4 is fixed with rivets 5 to a cylindrical boss 9 without a flywheel ring portion, a hexapole star-shaped magnet 6 is tightly attached to the inside of the magnetic pole piece, and a non-magnetic metal 7 such as aluminum is attached to the magnetic pole plate 4. A flywheel ring 31, which is formed by die-casting and then punching a steel plate, is placed around the boss with an annular gap and is placed in contact with the magnetic pole arm 42.

Thereafter, a connecting member 10 formed by molding or punching another metal material such as a mild steel wire rod into a substantially ring shape as shown in FIGS. Connection is achieved by applying pressure with a mold 11 between the concave grooves 91 and 311 formed in advance on the inner circumferential surface of the disc member of the flywheel ring to cause plastic flow.

The depth of the grooves 91, 311 is desirably about 0.1 to i.o.m. If it is too shallow, sufficient shear strength cannot be obtained, and if it is too deep, a large pressing force is required to insert the coupling member.

In the joining process, first, as shown in FIGS. 5 and 6, the joining member 10 is inserted into the gap 32 between the boss 9 and the flywheel ring 31.

Next, the gap width T.

Pressure part 12 of mold 11 having a smaller width tip surface t
Pressure is applied to the connecting member 10 to form grooves 91, 311 due to plastic deformation.
The coupling member 10 is introduced into the container.

The insertion step shown in FIG. 5 may also be performed using the mold 10.

In the state shown in FIG. 5, the coupling member 10 is surrounded by a gap 32 except for the upper end portion corresponding to the mold 11, and the difference in axial length ΔH is extremely small.

Therefore, it can be said that the entire connecting member is surrounded in the state immediately before pressurization.

Therefore, as shown in FIG. 6, the coupling member hardly escapes from the gap during processing.

As shown in FIG. 6, the pressurizing protrusion side surface 13 of the mold 11 is inclined by θ with respect to the direction perpendicular to the distal end surface 12 (insertion direction).

θ is preferably about 6° to 15°.

This is because if θ is small, it becomes difficult for the mold 11 to come out after bonding.

In addition, if θ is too thick, the joining member will easily flow out of the gap in the opposite direction to the insertion direction of the mold, and the insertion depth will not be deep enough, which will generate large internal stress in the joining member. Therefore, it becomes difficult to obtain a large bonding force.

As shown in FIG.
In other words, the distal end surface 12 is as close to the grooves 91, 311 as possible.
It is desirable to insert it deeply so that it is close to .

This reduces friction loss associated with plastic flow,
The binding agent can be fully inserted into the groove.

In order to maintain the above configuration, the material of the flywheel ring 31 and the boss 9 must be harder and have greater rigidity than the coupling member 10.

That is, the coupling member 10 connects the flywheel ring 31
, the material must have a lower deformation resistance than the boss 9.

For example, if the flywheel ring is made of mild steel, copper, aluminum, or the like may be used as the coupling member.

By inserting the joining member 10 into the gap 32 and filling it by applying pressure with a mold, the joining member is locally plastically deformed and the internal pressure increases, that is, an elastic stress larger than the yield stress of the joining member is generated. , a force that tries to respond to the outside acts.

A tension force is therefore generated in the radial direction in the connecting part.

Furthermore, the grooves 91° 311 generate shearing force against external forces in the axial direction, and both provide a strong bonding force.

Further, regarding the shape of the joint groove, there are examples shown below when a large rotational torque is required.

First, a predetermined gap portion having a groove in each joint surface is formed between the mutually opposing joint surfaces of two members to be joined.

Smaller uneven portions are formed at the bottom of each groove.

On the other hand, a simple-shaped joining member having a height at or close to the height of the gap is fabricated from a material that has lower deformation resistance than the members to be joined and has a predetermined mechanical strength.

Next, the coupling member is inserted into the gap.

At this time, substantially the entirety of the coupling member is surrounded by the gap and the mold ζ.

In this state, the joining member is cold-pressed by the convex portion of the mold to cause plastic flow in the groove in the gap, thereby joining the two-wave joining objects.

First, in FIG. 7, the first coupled member 110 and the second
Both members 120 to be joined are metal discs, and a ring-shaped gap 140 having a width To and a height Ho is interposed between the joining surfaces 111 and 121 of both members.

110c and 120c are end faces.

Additionally, grooves 112 and 122 are provided in the direction perpendicular to the surface, respectively.

As shown in FIGS. 8 and 9, small uneven portions 112a (or 122a) are provided on the bottom surface of the valley groove along the circumferential direction.

The depth hlo of the bottom surface of the groove 112° 122 to the center line mm of the uneven part is 0.2 to 1.07J, preferably 0.2 to 0.
Approximately 57'J is good.

In addition, the average height hll of the uneven parts on the bottom surface is 0.2 to 1.0.
The thickness is preferably about 0.2 to 0.5M.

On the other hand, 130 is a joining member similar to the above, which is made of a metal that is more easily plastically deformed than the joined members 110 and 120, that is, has less deformation resistance, and the width T1 is approximately equal to To.
It is slightly smaller or has a height Hl equal to or less than that of HO or slightly higher.

Even when Hl is higher than Ho, the difference ΔH is preferably kept as small as possible, for example, about 0.2 to 0.371 gl1.

In addition to the rectangular cross-section shown in the figure, the cross-sectional shape of the connecting member is round,
It may have a simple shape such as an ellipse or a polygonal cross section.

There is no need for the gap shape to be plastically deformed after insertion.

The joining process is exactly the same as in the case of the groove.

As described above, according to the present invention, the boss has a simpler shape and is easier to manufacture, and since there are no extra accessories when die-casting the rotor, the mold structure is simpler. The efficiency of molding work has also improved.

The flywheel ring, which is a separate piece, can be manufactured easily and inexpensively by punching with a press or the like.

Also, you can freely choose the material. Since joining the flywheel ring is the final process, it can be easily joined with the required size and force, simplifying the shape of the parts, improving productivity, and improving ease of assembly, reducing costs. 1
It can be obtained about 0% lower.

The next ζ mechanical ζ is as shown in Figure 2, arrow F.
1. In the shear test (static strength) in the F2 direction, when the connecting member is made of mild steel, it is stable at 32 K'; l/md.

The most important mechanical strength for a magnet generator is to have sufficient surplus power for angular acceleration and impact.

The bonding method of the present invention guarantees high strength and reliability that fully satisfies the required specifications.

[Brief explanation of the drawing]

FIG. 1 is a longitudinal cross-sectional view of the main part of a conventional magnet generator, FIG. 2 is a longitudinal cross-sectional view of the main part of a magnet generator according to an embodiment of the present invention, and FIG.
, FIG. 4 is a diagram showing an example of the shape of the joining member of the present invention, FIGS. 5 and 6 are explanatory diagrams of the joining process and joining state according to the invention, and FIG. 7 is another example of the joining member before joining. A partial cross-sectional perspective view showing the main external appearance of the members to be joined and the joining member, FIG. 8 is an enlarged view of the groove provided in the joining member, and FIG. 9 is the IX of FIG. 8.
-IX sectional view. 9...Boss, 10...Connection member, 31
...Flywheel ring.

Claims (1)

[Claims] 1. A boss rotated by a drive shaft, a flywheel ring concentrically and integrally arranged and fixed to one end of the outer periphery of the boss, and a flywheel ring fixed to the outer periphery of the boss via a non-magnetic metal material. In the rotor of a magnet generator, the rotor is equipped with a permanent magnet and a magnetic pole piece that closely surrounds the permanent magnet. a flyhole ring which is arranged in a circular manner and has an annular groove formed on a surface facing the groove, and a ring-shaped metal coupling member which is press-filled into the annular groove and the annular gap and is coupled with shearing force and tension force. A rotor for a magnet generator characterized by comprising: 2. A rotor for a magnet generator as set forth in claim 1, wherein the annular groove has an uneven portion formed on the bottom surface. 3. A boss rotated by a drive shaft, a flyhole ring concentrically and integrally arranged and fixed to one end of the outer periphery of the boss, a permanent magnet fixed to the outer periphery of the boss via a non-magnetic metal, and the permanent magnet In a rotor of a magnet generator equipped with magnetic pole pieces tightly surrounding a magnet, an annular gap is formed between the outer periphery of the mutually opposing bosses and the inner periphery of the flyhole ring, and An annular groove is formed on the outer periphery of the opposing boss and on the inner periphery of the flyhole ring, respectively, and has a lower deformation resistance than the material of the boss and the flyhole ring, and is equal to or approximates the length in the axial direction of the annular gap. A substantially ring-shaped metal coupling member having an axial length of The method is characterized in that the connecting member is surrounded by the bottom of the magnetic pole, and then the connecting member is pressurized by a mold convex portion to cause local plastic deformation in the groove portion, and the connecting member is connected by shearing force and tension force of the connecting member. A method of manufacturing a rotor for a magnet generator.