JPS6048988B2 - magnet generator rotor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a rotor for a magnet generator, and particularly to a rotor structure for a magnet generator suitable for use in a magnet generator for motorcycles.

The magnetic pole plate of the rotor of the conventional magnet generator of this type is disclosed in Japanese Patent Application Laid-open No. 1983
As shown in Japanese Patent No. 64806, it is generally crimped and fixed to the boss flange using rivets.

This is because the joint is driven by an engine, which requires a large rotational torque. However, with such a coupling method, it is difficult to shorten the total length of the rotor while ensuring a certain level of mechanical strength. In other words, from a design standpoint, the rotor in this type of generator has (a) a normal rotation speed of 11, OOORPM, no problem, and a rotation speed of 22, OOO
It must satisfy various conditions such as not being destroyed by RPM, and being able to withstand thermal changes from ←→-40°C to 180°C.

Taking these conditions into consideration, conventionally the rotor boss flange and the wheel main yoke were crimped and fixed using rivets, but the rivet holes and piston dimensions for rivet crimping were made with high dimensional accuracy. If it is not finished, it will not be possible to meet the required strength after caulking, and the difference in loosening of the rivets will become a problem. Therefore, of course, the processing cost of parts,
Assembly costs were rising. An object of the present invention is to provide a mechanically stable and compact rotor structure for a J-magnet generator, and a method for manufacturing the same.

The feature of the present invention is that a three-ring shaped gap is provided between the outer circumference of the boss and the inner circumference of the magnetic pole plate, and a groove is provided along the entire inner and outer circumferences of each, and a ring-shaped coupling member is inserted between the gaps to connect the outer circumference of the magnetic pole plate. The point is that the bonding force is obtained by the shear force and tension force of the members.

An embodiment of the present invention will be described below with reference to FIGS. 1 to 10.

First, in FIG. 1, a cylindrical boss 300 and a magnetic pole plate 20
0 are connected by a connecting member 100.

The boss 300 has a tapered portion 301, and a drive shaft (not shown) having a corresponding tapered portion is inserted into the boss and fixed with a nut. As shown in FIG. 2, the magnetic pole plate 200 includes a magnetic pole piece 201, a magnetic pole piece 202, and a disk portion 20.
It consists of 3. 400 is a hexapole star magnet.

500 is aluminum, and the magnetic pole plate, magnet, etc. are integrated by aluminum die-casting.

A groove 2 is formed in each joint surface between the mutually opposing joint surfaces between the inner periphery of the cylindrical portion 203 of the magnetic pole plate 200 and the outer periphery of the boss 300.
11,311 is formed.

Smaller uneven portions 212 and 312 are formed at the bottom of each groove portion. On the other hand, a ring-shaped joint with a simple cross-sectional shape having the height of the gap or a height similar to the height of the gap is made of a material, such as mild steel, that has lower deformation resistance than the members to be joined (magnetic pole plate, boss) and has a predetermined mechanical strength. The member 100 is processed. Next, the coupling member 100 is inserted into the cavity 240. At this time, substantially the entirety of the joining member 100 is connected to the member to be joined and the mold! To do something that is surrounded by something. In this state, the joining member 100 is cold pressed by the convex portion of the mold to cause plastic flow into the cavity grooves 211, 311, thereby joining the two objects to be joined. Next, the shape of the joint portion will be explained in more detail with reference to FIGS. 3 to 5.

There is a width T between the connecting surfaces of the magnetic pole plate and the boss.

, a ring-shaped cavity 240 with a height ratio of . Furthermore, grooves 211 and 311 are provided in a direction perpendicular to the surface of the joint.

The bottom of each groove has a small uneven portion 212 along the circumference of the circle.
(or 312) is provided. The depth HlO from the bottom surface of the grooves 211, 311 to the center line m-m of the uneven part is 0.2~
1.0w1n, preferably about 0.2 to 0.5TW1. In addition, the average height Hl of the uneven portions 212, 312 on the bottom surface
O is also 0.2 to 1.0 mHL1, preferably 0.2 to 0.5
? Good condition. On the other hand, 100 is a joining member made of a metal that is more easily plastically deformed than the joined members 9 and 11, that is, has less deformation resistance, and has a width T1.

The height H1 is approximately equal to or slightly smaller than the mountain, and the height H1 is equal to or slightly higher than the mountain. Even if H1 is higher than H'o, the difference ΔH is as small as possible, for example 0.2~
It is preferable to limit it to about 0.3 TI$t.

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. It is not necessary to take the shape of a cavity to cause plastic deformation after insertion.
The coupling member may be in the form of a complete ring, as shown in FIG. 6, or may have a gap S, as shown in FIG.

The former can be manufactured by sintering or the like, and the latter can be manufactured by bending a wire or the like. The gap S of the coupling member shown in FIG. 7 should be sized to be approximately zero when the coupling member is inserted into the cavity 240 (FIG. 8). In the joining process, first, as shown in FIG.
is inserted into the gap 240 between the magnetic pole plate 200 and the boss 300. Next, as shown in FIG. 9, the whole is placed on a mold 40, and the cavity width T is set.

Pressure part 3 of mold 30 having tip surface 31 with smaller width
2, the joining member 100 is cold pressed, and the groove 2 is formed by plastic deformation.
The coupling member 100 is flowed into 11,311. The insertion step shown in FIG. 8 may also be performed using the mold 30. In the state shown in FIG. 8, the joining member 100 is surrounded by the members 200, 300 to be joined except for the upper and lower end portions corresponding to the molds 30, 40, and the height difference ΔH is extremely small. Therefore, it can be said that in the state immediately before pressurization, the entire joining member is surrounded by the member to be joined and the mold. Therefore, as shown in FIG. 9, the coupling member hardly escapes to the outside of the gap when pressurized. As shown in FIG. 9, the pressurizing projection side surface 33 of the mold 30 is inclined by 0 with respect to the direction perpendicular to the tip surface 31 (insertion direction).

It is desirable that θ is about 6 to 15). This is because if θ is small, it becomes difficult for the mold 30 to come out after joining. Furthermore, if θ is too large, the joining member tends to flow out of the cavity in the opposite direction to the insertion direction of the mold, and the insertion depth cannot be deepened, causing large internal stress in the joining member. Therefore, it becomes difficult to obtain a large bonding force. As shown in FIG. 9, the mold pressurizing part 32 has a distance S between its tip surface 31 and the upper ends of the grooves 211, 311 as small as possible, in other words, the tip surface 31 is as close to the groove 2 as possible.
It is desirable to insert it deeply so that it is close to 11,311.

This reduces friction loss associated with plastic flow,
The coupling member can be fully inserted into the groove. In order to maintain the above configuration, the materials of the magnetic pole plate 200 and the boss 300 must be harder and have greater rigidity than the coupling member 100.

That is, the coupling member 100 includes the magnetic pole plate 200 and the boss 30.
The condition is that the material has a deformation resistance smaller than 0.
For example, the magnetic pole plate is made of cold rolled steel plate (SPCC) and the boss is also made of steel (
SF material), the connecting member may be mild steel, aluminum,
Possible materials include copper.

By inserting the coupling member 100 into the cavity 240 and filling it, a tension force is generated in the coupling portion in the radial direction. Furthermore, the grooves 211 and 311 generate a shearing force in response to an external force in the axial direction, and both provide a strong bonding force. An example of a conventional magnet generator rotor is shown in FIGS. 10 and 11.

The magnetic pole plate has a magnetic pole piece 201, a magnetic pole arm 202, and a disk portion 203, as in the previously described embodiment of the invention. On the other hand, the boss 300 has a cylindrical portion 302 and a flange portion 303. The magnetic pole plate 200 is crimped and fixed into a rivet hole formed in the boss flange portion 302 with a rivet 306 formed from a mild steel wire for rivets.

The six-pole star-shaped magnet 400 is closely attached to the inner periphery of the magnetic pole piece 201, and these are integrally molded from aluminum 500.

In order to shorten the overall length in such a structure, it is possible to reduce the thickness of the pole piece material, the thickness of the collar member, and the height of the stud head, but it is not possible to reduce the material thickness. It cannot be put to practical use because its mechanical strength is poor. On the other hand, according to the present invention, as described above, structurally, the studs 306 and the flange portion 303 of the boss 300 are unnecessary, so that the axial direction can be shortened.

The effect is that the axial length can be significantly reduced by about 15%, making it possible to reduce the size and weight, and at the same time, lead to the miniaturization of the engine itself equipped with this magnet generator. Also, since the boss does not require a tsuba, it has a simple shape and improves productivity. Next, mechanically, as shown in FIG. 1, the static strength is stable at 32k9/i when the connecting member is made of mild steel in a shear strength test in the directions of arrows Fl and F2.

The most important mechanical strength for a magnet generator is that it has enough extra power to withstand angular acceleration and impact. In this respect, in the case of riveting, there is a slight gap and is therefore unstable, whereas the present invention uses a joining method with no gaps, so high reliability is guaranteed. Furthermore, the rotational torque becomes increasingly large due to the small uneven portions 212, 312 provided at the bottom of the groove.

11 to 14 show other embodiments of the present invention.

In this example, a six-pole star magnet 400 is connected to two magnetic pole plates 200.
A, 200B are sandwiched so that they are narrow, and the rotation prevention force of the magnet is divided between two fixed parts. That is, concave grooves 311 provided on the left and right sides of the outer circumference of the cylindrical boss 300
Magnetic pole plates 200A, 20 are placed opposite A, 311B.
Concave grooves 211A and 211B are provided on the inner periphery of 0B, and the six-pole star magnet 400 is sandwiched and placed therein, and the coupling member 100 is inserted into the space between the boss and the magnetic pole plate, and then molded with a mold. Both are bonded by pressing and plastic deformation in the same manner as described above.

In this case, the bottom surface of the coupling member is received by a stepped portion provided on the boss instead of the metal mold described above. With this method, the left and right sides of Figure 12 are
The star-shaped magnet is joined at two places to prevent rotation, and is integrally molded from aluminum 500. In addition, 201A
, 201B are magnetic pole pieces. This method is effective when a large magnet is used and the strength is insufficient to connect it at one location. Also, the magnetic pole plate is divided into two parts.
By using 00A and 200B, the width of the magnetic pole arm can be increased to prevent the magnetic pole plate from floating during high speed rotation, thereby improving the strength.

Furthermore, in the magnetic pole plate shown in Figure 11, the magnetic flux between the N and S poles that are adjacent to each other leaks between the magnetic pole arms, causing a decline in electrical performance. Since the divided magnetic pole pieces can prevent leakage of magnetic flux between the magnetic pole arms, electrical performance can be improved by about 2 to 5%.

As described above, according to the present invention, compared to conventional joining methods such as riveting, the fastening strength is stably high, the axial structural dimension is small, and the pressure assembly is excellent. There is an effect.

[Brief explanation of the drawing]

Fig. 1 is a longitudinal cross-sectional view of the magnet generator rotor of the present invention, Fig. 2 is a view showing the front upper half of the magnetic pole plate in Fig. 1, and Fig. 3 shows details of the configuration of the coupling part in the present invention. FIG. 4 is a vertical sectional view showing details of the groove on the magnetic pole plate side, and FIG. 5 is a sectional view taken along the line V-V in FIG. 4. 6 and 7 are external perspective views showing embodiments of the coupling ring according to the present invention, FIGS. 8 and 9 are longitudinal cross-sectional views of main parts showing the coupling method according to the present invention, and FIG. The coupling ring is shown inserted into the cavity, and FIG. 9 shows the coupling ring plastically deformed using a mold.
Figure 10 is a vertical cross-sectional view of the rotor of a conventional magnet generator.
FIG. 1 is a cross-sectional view taken along line AA in FIG. 10. FIG. 12 is a longitudinal sectional view showing another embodiment of the rotor of the magnet generator of the present invention, FIG. 13 is a front view of the magnetic pole plate in FIG. 12, and FIG. This figure shows the B cross section.
100... Connecting member, 200... Magnetic pole plate, 300... Boss, 211... Groove,
311...Groove, 240...Void portion.

Claims (1)

[Claims] 1. A boss attached to the drive shaft, arranged on the outer periphery of the boss,
In a rotor of a magnet generator equipped with a magnetic pole plate coupled to each other to hold a permanent magnet, an annular gap is provided between the outer periphery near one end of the boss and the inner periphery of the cylindrical part of the magnetic pole plate, and an annular gap is provided in the gap. Annular grooves are provided on the outer periphery of the boss and the inner periphery of the cylindrical part of the magnetic pole plate at corresponding positions, and an annular coupling member made of a metal material is filled in the gap and the annular groove to reduce tension and shearing force of the coupling member. A rotor of a magnet generator that obtains the bonding force between the magnetic pole plate and the boss. 2. A boss attached to the drive shaft, arranged on the outer periphery of the boss,
A rotor of a magnet generator is equipped with a pair of magnetic pole plates that are coupled together and hold a permanent magnet, and is configured to sandwich a permanent magnet so that each magnetic pole plate has the same polarity. On the other hand, annular gaps are provided between the outer periphery near both ends of the boss and the inner peripheries of the cylindrical portions of both magnetic pole plates, and annular grooves are provided on the outer periphery of the boss and the inner peripheries of the cylindrical portions of the magnetic pole plates at positions corresponding to the respective gaps. The gap and the annular groove are each filled with an annular coupling member made of a metal material, and the coupling force between the magnetic pole plate and the boss is obtained by the tensile force and shearing force of the coupling member. Magnet generator rotor. 3. A rotor for a magnet generator according to claim 2, wherein each coupling member is made of mild steel.