JPS601821B2 - Rotor of magnet generator and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a rotor for a magnet generator, which is 4-shaped and has high strength.
Moreover, it relates to a highly accurate structure and manufacturing method.

The rotor boss flange and flywheel yoke were fixed with rivets, but the vertical holes and pitch dimensions of the rivets were
Unless finished with high dimensional accuracy, it will not be possible to satisfy the required strength after caulking, which will eventually lead to problems such as loosening of the rivets. Naturally, therefore, the processing costs and assembly costs for parts are high. An object of the present invention is to provide a rotor for a magnet generator that is mechanically stable and compact, and its manufacture.

The present invention is characterized by providing a groove all around the outer periphery of the boss, further providing unevenness along the circumferential direction on the bottom surface of the groove, and inserting a part of the flywheel yoke into the groove while being plastically deformed. The point is that it has a bonding force.

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

First, in FIG. 1, reference numeral 1 denotes a drive shaft of an engine, and a tapered portion 2 is formed at one end of the drive shaft. Reference numeral 3 denotes a cylindrical boss made of carbon steel for machine structural use, which has a cam on its outer periphery and a keyway 33 formed on its inner side, and is fitted into the tapered portion 2.

A nut 6 is screwed onto the end of the drive shaft 1 and presses the cylindrical boss 3 onto the tapered portion 2 with a washer 7 interposed therebetween.

9 is a flywheel main body, and has a flywheel yoke 10 made of a mild steel plate formed into a cup shape, and permanent magnets 11 and magnetic pole pieces 12 are arranged alternately on the same circumference around the drive shaft 1. The inner surface of the magnetic pole piece 12 faces the fixed iron core 14 around which the generating coil 13 is wound, with an air gap interposed therebetween.

16 is an ignition interrupter, and a shaft 18 is fixed to the board 17 in a camellia position.
An arm 19 inserted into the engine case is operated by a cam formed on a part of the outer periphery of the boss 3, and the base plate 17 is fixed with screws to a generator base plate 201 fixed to the engine case and a fixed iron core 14. A positioning hole 23 is provided in the flywheel yoke 10'. Flywheel yoke 1
The inner end of the disk portion 101 of No. 0 is directly fixed to the outer periphery of the boss 3.

The configuration of this part will be explained in detail below. In FIG. 2, a groove 31 is provided on the outer periphery of the flap portion of the boss 3, and a knurling 32 as shown in FIG. 3 is provided at the bottom of the groove.

The average depth Ho of the groove is 0.2 to 1. The height of the rib and knurling is also 0.2 to 1. Good as a revenge. The angle of inclination of the groove ends is preferably about 25° to 70°. On the other hand, the flywheel yoke 10 is made of steel (SP
As shown in FIG. 4, the disk portion 101 has a thickness t that is thicker than the width B of the groove 31 of the boss, and has an outer diameter D. It has a hollow portion 102 with a diameter of approximately equal to (loose fit) ○2.

Figure 5 shows the process of connecting the flywheel yoke and post.

3 is a boss, and a lower die 4001 installed on a bolster 410 of the press is held in a concave portion 401. On the other hand, the flywheel yoke 10 is held by the flat part 402 of the lower die.

In this state, the groove 31 of the boss and the flywheel yoke 10 are placed at predetermined positions. A male mold 500 is arranged in the hollow part of the upper presser plate 300.

Reference numeral 601 is a male mold bed, which is connected to a slide 602.
Spring presser upper plate 603, spring 604, imitation presser lower slope 60
5. The spring guide 606 connects the slide 602 and the upper presser plate 3
It is located between 00 and 00. The spring presser upper plate 603 is fixed to the slide 602. Further, the upper retaining plate 30 is held by the spring retaining upper plate 603 via bolts 607 at the upper arm 303 portion. In the joining process (cold), as the slide 602 descends, the male die 501 and the male die 5
00, the upper presser plate 300 is descending, but the upper presser plate 30
Since there is a gap between the arm 303 of 0 and the head of the bolt 607, the end face of the flywheel yoke 10 is pressed by the flat part 302 of the upper holding plate 300 before pressurizing the flywheel yoke 10 with the male die 500. be pressured.

This pressing force is applied from the slide 602 to the spring retaining upper plate 603,
It is applied via a spring 604 from a direction perpendicular to the end face of the flywheel yoke 10. As a result, a prestress oo is applied to the flywheel yoke in a direction perpendicular to the flat parts 302 and 402 of the lower die and the upper holding plate.

This prestress is smaller than the deformation resistance of the disk. When the slide 602 further descends in this state, the tip 501 of the male die 500 pressurizes the vicinity of the hollow portion of the flywheel yoke 10.

At this time, the deformation resistance of the disk is 0, but the stress is greater than that.
2 acts, and this stress 02 plastically deforms the part of the flywheel yoke near the hollow part 102, and the groove 3 of the boss 3
1.

The flywheel yoke 3 is pressurized from its upper and lower surfaces in advance,
Since the prestress oo is generated, plastic deformation of the flywheel yoke when pressurized by the male die 500 is limited to only a portion close to the hollow portion 102, and deformation of other portions is prevented.

This allows a portion of the flywheel yoke to flow sufficiently into the knurling of the groove 31. If the flywheel yoke is made of steel (SPHC).

o = 5~15k9/fence,. 2 = 150~180k9
/ It is best to make it about the size of a square.

The preload required for this is about 30 tons when the outer diameter of the flywheel yoke is 10 mm, and the load by the male die 500 is about 30 to 40 tons. FIG. 6 shows the appearance after completion of bonding. The flywheel yoke 1 has a recess 103 formed when it is pressurized by the tip 501 of the male die 500, and its depth h is about 1 to 2 times the depth of the groove, which is the desired value. Better is 0.6-1. Good as a revenge. The volume v (FIG. 7) of the recess 103 should be determined such that a portion of the flywheel yoke sufficiently flows into the groove 31.

To do this, it is necessary to set the total amount of the amount corresponding to the volume V of the groove 31 and the amount escaping to other parts, such as the amount by which the flywheel iron extends outward in the radial direction.

If a preload is applied to the lower end surface of the flywheel yoke, the amount of escape to other parts will be relatively small, and v = 1.5V ~
Approximately 2.0V is sufficient. If the recess depth h is increased in order to ensure Z, the thickness of the flywheel yoke becomes thinner, causing stress concentration in that portion and lowering the strength. Also,
If the distance S from the bottom of the recess 103 to the top of the groove 31 is very small, or on the negative side, the groove Z3
The tension of the material inserted into 1 is released, and the bonding force is reduced. In this way, there are certain restrictions on the recess depth h.
For the above reasons, the relationship between the width b of the recess 103 and the width B of the groove 31 is 0. Yumi bSI. It is preferable to use it as porridge.

It is preferable that the recessed portion 103 be as close as possible to the green end of the hollow portion of the flywheel yoke.

If it is far from the inner edge, the material of the flywheel yoke will escape upward or radially outward when pressurized by the male die 500, and will not be inserted effectively into the two grooves 31. Therefore, the recess 10
Considering the ease with which the tip 501 of the male mold 500 can be removed, the position No. 3 is preferably set slightly outside the inner edge in the radial direction. It is desirable that the ratio S/b between the width b of the recess 103 and the distance S from the bottom of the recess 103 to the upper end of the groove 313 is within a certain range.

FIG. 8 shows experimental data for determining the relationship between S/b and the cross-sectional area of the gap created in the groove due to insufficient material flow during bonding.

Note that the groove depth, the inclination angle Q (45o) of the groove end, and the pressing force are all equal. In a range where S/b is small, there are almost no gaps except at the corners of the groove.

When S/b exceeds 3/4, a gap appears at the bottom of the groove, and when S/b exceeds 1, it increases rapidly. This is because as S increases, the distance from the leading edge of the male die to the groove increases, and the frictional resistance when the material plastically flows between them increases, causing other parts of the flywheel yoke to deform due to the pressure exerted by the male die. This is because, for example, the flywheel yoke extends in the radial direction. The same result is obtained even if the pressing force is increased. As the gap within the groove 31 becomes larger, the tension force on the material inserted into the groove becomes smaller and the bond strength decreases significantly.

For these reasons, it is desirable to set S/b to 3/4 or less. On the other hand, when S is less than a drop, that is, on the negative side, as described above, the tension of the material inserted into the groove 31 does not increase, and the bonding strength decreases.

Taking all the above points into consideration, it is desirable that S/b has the following relationship. .

≦S/b≦Figure 9 shows the results of determining the strength of the combined body with respect to the torque.

The solid line shows the method of the present invention, and the broken line shows the method of the conventionally known knurling press-fitting method. The test material is
The boss is S3*, and the disk corresponding to the flywheel yoke is S.
It is PHC. Also, the outer diameter of the disk ○ = 10 ribs, the plate thickness t =
5 skins, groove width B = 2 ribs, groove depth H = 0.4 side, a = 450
It is. In addition, the knurling press-fitting method forms a knurl on the outer periphery of the shaft (outer diameter d), and a hollow disc (inner diameter d, outer diameter ○
, plate thickness t), and the material is the same. 5 According to the method of the present invention, when the boss outer diameter is, for example, 28 fences,
The rotating torque is 9-100k9.

In the knurling press-fitting method, the material does not flow in sufficiently even near the center of the o-let, and the actual cross-sectional area of the chick is small.
Therefore, the rotating torque is small. In contrast to this, in the present invention,
In the vicinity of the center of the knurled portion, the material sufficiently flows into the groove, and as a result, the cross-sectional area becomes large, and as a result, the shearing force becomes large, and the tension force also becomes large. Applying a preload to the entire end face of the flywheel yoke before applying pressure with the male die is also effective in preventing warping of the plate surface.

If no preload is applied and pressure is applied only with the male die 500, warpage will occur.

The outer diameter D of the flywheel yoke is 100 ribs and 0.
A warpage of 3 to 0.7 degrees occurs. For the purpose of preventing this and ensuring that material is effectively inserted into the premises,
Preload 20. =0.3 to 1.0202.
FIG. 10 shows another embodiment of the present invention, in which the boss 3 has a metal part 35, a groove 31 is provided on its outer periphery, and a flywheel yoke 10 is fixed thereto.

Note that 36 is a screw used when disassembling the flywheel yoke 10 and boss 3 assembly from the drive shaft 1. A flange portion 35 is provided, and the flywheel yoke 10 is provided at this portion.
By joining, the radius of the joined part becomes larger,
Mechanical strength is improved.

For example, the outer diameter of the boss is 54 ribs, the flywheel yoke is 10
A flywheel yoke with an outer diameter of 15 mm and a wall thickness of 5 mm has a flange with an outer diameter of 66 ribs and a wall thickness of 7 to 1 mm (
The groove conditions are the same), and when they are connected, the rotational torque is 1.
The needle sound, the pulling force in the direction of the ball is 1.22 times, and the vibration intensity at the resonance point is 1. The sound sealing level has improved. In the present invention, instead of providing knurling at the groove bottom, other suitable means may be used to provide corrugated portions or other uneven portions within the groove. This uneven portion contributes to an increase in rotational torque,
Any material may be used as long as it is easy to process and is compatible with the plastic flow of the material. According to the present invention, when the flywheel yoke and the boss are directly connected, a mechanically strong connection can be obtained, and workability is also excellent because the joining operation is performed by a cold plastic working method.

[Brief explanation of the drawing]

FIG. 1 is a longitudinal sectional view of a main part of a magnet generator according to an embodiment of the present invention. FIG. 2 is an external view of the boss before coupling, and FIG. 3 is a cross-sectional view of the groove portion of the boss in FIG. 2. FIG. 4 is a diagram showing a longitudinal section of the flywheel yoke before connection. FIG. 5 is a diagram showing a joining process using a press, and FIG. 6 is an external perspective view after joining. FIG. 7 is an explanatory diagram of the dimensional relationship between the disk and the post part in the present invention, and FIG. 8 is an S/b diagram in the present invention.
FIG. 9 is a diagram showing the results of determining the rotational torque for the coupling method of the present invention and the conventionally known knurling press-fitting method. FIG. 10 is a longitudinal sectional view of a main part of a magnet generator according to another embodiment of the present invention. 1
...Drive shaft, 3...Boss, 10...
...flywheel yoke, 31...book, 32
...Knurling. Figure 2: Resurrection Figure 4: Figure 1: Figure 5: Figure 6: Trying Figure 8: Lo Figure: Younger brother q

Claims (1)

[Claims] 1. A drive shaft comprising a boss fixed to a drive shaft, and a substantially cup-shaped flywheel yoke arranged concentrically around the outer circumference of the boss and having a permanent magnet arranged on the inner circumferential surface. In the rotor of the magnet generator, a groove having an uneven bottom surface is formed along the circumferential direction on the outer periphery of the boss, and a part of the flywheel yoke is plastically deformed in the groove and the uneven area. A rotor for a magnet generator, characterized in that it is filled and a boss and a flywheel yoke are combined. 2. A rotor for a magnet generator according to claim 1, wherein the material of the boss is carbon steel for mechanical structure, and the material of the flywheel yoke is mild steel. 3. A rotor for a magnet generator that includes a boss fixed to a drive shaft and a substantially cup-shaped flywheel yoke that is arranged concentrically around the outer circumference of the boss and has a permanent magnet arranged on the inner circumferential surface. In this process, the flywheel yoke is pressurized in advance from its upper and lower surfaces by a mold, and the hollow vicinity of the flywheel yoke is pressurized with a stress greater than the deformation resistance of the flywheel yoke to deform the flywheel yoke. A magnet characterized in that a portion near the hollow portion is plastically deformed so as to flow into a groove formed on the outer periphery of a boss made of a material larger than the deformation resistance of the flywheel yoke, and which has an uneven bottom surface for coupling. A method of manufacturing a generator rotor.