JPH027264B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a rotor for a magnet generator and a method for manufacturing the same, such as a rotor for a magnet generator mounted on a small or special vehicle such as a motorcycle or buggy. Concerning what is effective when used.

[Conventional technology]

Generally, a magnet generator as shown in FIG. 6 is sometimes used in small or special vehicles such as motorcycles and buggies. This generator has a plurality of ferrite magnets (hereinafter referred to as magnets) on the inner peripheral surface of a cylindrical yoke 2.
A rotor 1 consists of a magnetic unit configured by arranging and fixing magnets 3 in the circumferential direction with equal phase difference from each other, and a core 5 made of laminated thin iron plates. Coils 6 are respectively arranged at a plurality of radial locations on the outer periphery of the core 5. The rotor 1 is driven by the engine and rotates around the generator 4, so that an electric current is generated in each magnetic pole coil 6 of the generator 4. The device is configured to induce electric power.

In the conventional rotor of such a magnet generator, in order to prevent fragments from being scattered due to rotation when the fragile magnet is damaged, for example,
The structure of fixing the magnet to the yoke as shown in FIG. 7 or 8 surrounds the entire circumference of the magnet.

The structure shown in FIG.
At the same time as inserting one magnet into the protective frame 7, each pole piece 8 is brought into contact with the inner surface of the magnet 3A, and the outer surface of the magnet 3A is inserted from the outer periphery of the yoke 2 and screwed into the pole piece 8. It is designed to be tightened and fixed to the destination yoke.

In the structure shown in FIG. 8, a magnet 3A having a size equal to or larger than two magnets is fitted into a case 10 formed by integrating a protective frame 7A and two pole pieces 8A and 8B into a box shape. , After tightening and fixing this case 10 with screws 9, attach magnet 3B.
Two magnetic poles 3C, 3C are magnetically attached to each other, and by accomplishing the work of tightening and fixing two or more pieces at once, the decrease in productivity can be suppressed.

[Problem that the invention seeks to solve]

However, in the fixing structure shown in Fig. 7, after inserting one magnet into the protective frame,
Since each piece is tightened and fixed, there are problems in that the number of parts is large, it takes a lot of man-hours, it is difficult to automate the assembly work, and productivity is low.

In addition, in the fixing structure shown in Fig. 8, a neutral part (magnetic neutral part) 3D must be interposed in the expensive ferrite magnet, which results in a wasteful part and is uneconomical. There is a point.

[Purpose of the invention]

An object of the present invention is to provide a rotor for a magnet generator, which solves the problems of the prior art, and which can improve assembly workability without requiring the interposition of a neutral part within the magnet, and its manufacture. The purpose is to provide a method.

[Summary of the invention]

The present invention involves inserting a magnet into each storage chamber of an annularly arranged upper open frame, plastically deforming the partition wall of the storage chamber, and clamping and fixing the magnet from both sides. By press-fitting a substantially cylindrical cover into the aligned magnet group so that it tightly contacts the inward surface of each magnet, the magnet can be fixed to the yoke with a simple assembly process, and the magnet can be attached to the case and cover. It is designed to be protected by

〔Example〕

FIG. 1 is an exploded perspective view showing a rotor of a magnet generator according to an embodiment of the present invention, FIG. 2 is a longitudinal cross-sectional view showing its assembled state, and FIG. 3 is a longitudinal cross-sectional view showing its assembly in progress. FIG. 4 is a partially cutaway plan view, and FIG. 5 is a longitudinal sectional view.

In this embodiment, the rotor as a magnetic unit includes a yoke 11 and a plurality of magnets 12.
, a case 13 , a cover 14 , and a holding ring 15 .

The yoke 11 is integrally molded with a magnetic material into a substantially bowl-like shape with an open upper surface and a closed lower surface, and the lower closed wall has a shaft hole 16 in the center for inserting the boss portion. A plurality of mounting holes 17 for fixing the rotor to a boss (not shown) directly connected to the engine are drilled at each position. At the outer position of the mounting hole 17, there is a case 1.
A plurality of convex portions 18 for preventing rotation of the rotor 3 are protruded from the outer surface when the lower surface is closed, and the mounting holes 17 and the convex portions 18 are arranged at an arbitrary angle in the circumferential direction. . A winding margin 19 is formed at the upper end of the yoke 11 by cutting the outer periphery.

The magnet 12 has a height H greater than the depth of the yoke 11, and is integrally formed into a substantially rectangular parallelepiped having a circular arc shape curved along the inner circumference of the yoke 11 in the direction of the width W. At both ends of the arc-shaped inward surface (hereinafter referred to as the ventral surface) 20 of the magnet 12, inclined portions 22 are arranged such that as they go outward, they approach the arc-shaped outward surface (hereinafter referred to as the back surface) 21. each formed. The rising side surfaces 23 and 23, the upper surface 24, and the lower surface 25 on both sides are formed parallel to each other.

The case 13 is integrally molded by die-casting or the like using a non-magnetic metal material such as aluminum, and has a generally cylindrical shape that fits inside the yoke 11 as a whole. A plurality of storage chambers 31 are formed in the cylindrical wall 30 of the case 13 and arranged in the circumferential direction with substantially equal phase differences. The housing chamber 31 is formed into a hollow chamber having a height h that is less than the height H of the magnet 12 and a width w that is slightly larger than the width W of the magnet 12. Each section is open to the public. Therefore, the case 13 has a shape in which a plurality of frames each having an open top are connected in a ring shape.

The floor walls 32 of each storage chamber 31, ie, the lateral pieces of each open top frame, are adjacent to each other to form a series of rings 33, and the inner edges of the floor walls 32 of each storage chamber 31 are The protrusion 34 is formed in an arc shape. Between the adjacent storage chambers 31, 31, partition wall portions 35 corresponding to the vertical pieces of the upper open frame are formed to stand up in a columnar manner, and the wall thickness t of each partition wall portion 35 is equal to that of the magnet. It is formed slightly thinner than the wall thickness T of No. 12. A plurality of recesses 36 are arranged and recessed on the lower surface of the ring 33 so as to be directly below the partition wall 35 between the storage chambers 31 and 31, and each recess 36 is recessed into the convex portion 18 of the yoke 11. shaped to fit together.

The cover 14 is integrally formed by drawing press processing using a magnetic metal material such as a thin iron plate, and has a generally cylindrical shape that fits inside the case 13 as a whole. Before assembly, at the lower end of the cylindrical portion 37 of the cover 14, a lower flange 38 has a circular annular shape that protrudes radially inward, and at its upper end, an upper flange 39 protrudes radially outward. They are each formed in the shape of a circular ring.

The holding ring 15 is integrally formed by punching and pressing using a non-magnetic metal material, and is formed into a substantially annular shape having a notch 41 in a portion.

Next, by explaining the assembly work of a rotor of a magnet generator using each component according to the above structure, an embodiment of the method for manufacturing a rotor of a magnet generator according to the present invention and a magnet generator obtained therefrom will be explained. The configuration of the rotor will be explained below.

First, the case 13 is fitted into the yoke 11, and the concave portions 36 on the lower surface of the case 13 are fitted into the convex portions 18 raised on the bottom wall of the yoke 11, respectively. By fitting the convex portion 18 and the concave portion 36, the case 13 is prevented from rotating integrally with the yoke 11.

Subsequently, the magnets 12 are inserted into each housing chamber 31 of the case 13 from above. At this time, since the width w of the storage chamber 31 is formed to be slightly larger than the width W of the magnet 12, each magnet 12 can be easily inserted into each storage chamber 31.

After the magnets 12 are inserted into all the storage chambers 31 until they come into contact with the protrusions 34 on the floor wall 32, a concave shape is formed at the upper end of each partition wall 35, as shown in FIGS. 3 and 4. Plastic deformation part 42
are stamped simultaneously or separately using a pressing die (not shown) such as a wedge-shaped punch.

As the concave plastically deformed portion 42 is depressed, the wall at the upper end of the partition wall 35 expands and plastically deforms outward in the circumferential direction. By pressing the inserted magnet 12 from both sides, it is strongly fixed.

Then, inside the 12 groups of magnets that are housed and fixed in each housing chamber 31 of the case 13 and arranged in an annular shape, a cylindrical shape having an outer diameter that is approximately equal to the diameter of the circular inner peripheral surface formed by the 12 groups of magnets is formed. The cover 14 shown in FIG. 5 is press-fitted as shown in FIG. As a result, the outer peripheral surface of the cover 14 comes into close contact with the abdominal surface 20 of each magnet 12, but the wall thickness t of the partition wall 31 of the case 13 is formed to be slightly thinner than the wall thickness T of the magnet 12. Therefore, the outer circumferential surface of the cover 14 does not come into close contact with the abdominal surface of each partition wall 31.

During press-fitting, the flanges 38 and 39 are formed at the lower and upper ends of the cover 14, so even if the cover 14 is made of a thin iron plate, sufficient rigidity is ensured in the cylindrical portion 37. ing. Therefore, the cover 14 can be press-fitted into the case 11 smoothly, and the cylindrical portion 3 of the cover 14 can be press-fitted smoothly.
This is done so that the outer circumferential surface of the case 7 is in close contact with the inner circumferential surface of the case 14 uniformly throughout.

Further, since a jig for applying a pushing force or a reaction force opposing this to the cover 14 can be engaged with both the flanges 38 and 39 during press fitting, the press force is applied to the entire cover 14. This enables uniform biasing and more precise press-fitting.

Note that the lower flange portion 38 is then extended downward, and the cover 14 is formed into a cylindrical shape.

Thereafter, the presser ring 15 is applied to the upper flange 39 of the cover 14 that covers the upper end surface of the case 11, and the staking process is performed to press the staking margin 19 inward at the top end of the yoke 11. administered. As a result, the yoke 11, the magnet 12, the case 13, the cover 14, and the holding ring 15 are caulked and integrated.

In this way, the rotor of the magnet generator shown in FIG. 2 was manufactured.

That is, in this rotor, each magnet 12 is accommodated in each accommodation chamber 31 in the case 13 fitted into the yoke 11, and is connected to the partition wall 3.
5 and 35, and its abdominal surface 20 is covered by the cylindrical portion of the cover 14.

According to this embodiment, the magnets are inserted into the respective storage chambers formed in the case, and the concave plastic deformation portions are stamped on the partition wall of the case so that the magnets are held under pressure from both sides. The number of parts and assembly man-hours can be reduced, and work efficiency can be improved by eliminating the need for screws or rivets.Since each magnet is independent, it is possible to reduce the number of parts and assembly man-hours. There are no wasted parts and it is economically advantageous.

In addition, fitting the case into the yoke, inserting the magnet into the housing chamber of the case, fitting the cover onto the inner peripheral surface of the magnet group, and setting the retainer ring are all unidirectional assembly operations, so they are extremely difficult to assemble. It has good workability and can easily be fully automated.

When fixed with the yoke, the magnet is surrounded all around by the case and cover, so
Even if the magnet were to be damaged, the fragments would not be scattered, and it is possible to prevent the occurrence of secondary failures due to fragments flying away as the rotor rotates.

The magnet is clamped and fixed in the housing chamber of the case, and is closely covered by the cover, so the magnet will not move (rattle) due to the inertial force applied by angular acceleration during use. Wear, deterioration, destruction, etc. of each part can be suppressed.

By the way, in air-cooled engines such as buggies where the vehicle speed does not increase even when rotating at high speeds, the generator room and oil temperature rise significantly, and a severe heat shock is applied to the rotor of the magnet generator. Use resin to fix it to the yoke,
If adhesive is used, the resin may melt or
Adhesive strength may decrease. In such a case, if inertia is applied to the rotor, the magnets will not only float inside the yoke, reducing the functionality of the magnet generator, but in the worst case scenario,
There is a risk that the magnet will crack and scatter into the generator room, causing an unexpected situation such as the engine locking up.

However, in this embodiment, the magnet is housed and fixed in the housing chamber of the case made of a non-magnetic metal material, and is covered with a cover made of a magnetic metal material, so it is not susceptible to melting. There is no risk of a decrease in fixing force. Therefore, unforeseen situations such as a decline in the functionality of the magnet generator due to magnet drift caused by melting or a decrease in fixing force, and magnets being scattered can be avoided.

It should be noted that the present invention is not limited to the above-mentioned embodiments, and may be modified without departing from the gist thereof.
It goes without saying that various changes are possible.

For example, the case is not limited to being formed by aluminum die-casting, but may be formed by forging, sintering, etc. using aluminum or other non-magnetic metal materials.

Adhesive can also be used auxiliary for fixing the case and the magnet, the case and the cover, etc.

The anti-rotation structure between the yoke and the case is not limited to a structure in which a convex part raised on the yoke fits into a recessed part recessed in the case. It may also be a structure in which provided protrusions are fitted into each other.

〔Effect of the invention〕

As explained above, according to the present invention, magnets are inserted into each housing chamber of the case and fixed by being pressed from both sides by the partition wall, and a cylindrical shape is installed inside the group of magnets arranged in an annular shape. Since the cover is fitted to surround the magnet, productivity can be improved and the magnet can be fixed and protected for a long period of time.

[Brief explanation of drawings]

Figures 1 a, b, c, d, and e are exploded perspective views showing a rotor of a magnet generator according to an embodiment of the present invention, Figure 2 is a longitudinal sectional view showing its assembled state, and Figure 3 is a FIG. 4 is a partially cutaway plan view, and FIG. 5 is a longitudinal sectional view showing the assembly in progress. FIG. 6 is a plan view showing an example of a rotor of a general magnet generator, FIG. 7 is a partial plan cross-sectional view showing a conventional example,
FIG. 8 is a partial plan sectional view showing another conventional example. 1... Rotor, 2... Generator, 11... Yoke, 12... Magnet, 13... Case, 14
... Cover, 15 ... Holding ring, 16 ... Shaft hole, 17 ... Mounting hole, 18 ... Convex part, 19 ...
...Crimping allowance, 30...Cylinder wall, 31...Accommodation chamber, 35...Partition wall, 36...Concave portion, 37...Cylindrical portion, 38...Lower flange, 39...Upper flange , 41... Notch portion, 42... Concave plastic deformation portion.

Claims (1)

[Claims] 1. A yoke 11 formed in a bowl shape and having a crimping margin 19 formed at its upper end, and a ring 33 fitted into the yoke 11 and formed in a circular ring shape. Partition wall part 35 on the top surface
A plurality of partition walls 3 are arranged at intervals in the circumferential direction and protrude from each other at right angles.
Magnet housing chambers 31 are formed between each of the magnets 5 and 35, and are inserted into the case 13, which is integrally molded from a non-magnetic metal material, and each of the magnet housing chambers 31, and each of the partition walls. A plurality of magnets 12 are clamped and fixed between adjacent partition wall portions 35, 35 by plastically deforming the distal end portions of the magnets 35 in the circumferential direction by a pressing die, and the case 13 and the magnets 12. A cylindrical cover 14 is press-fitted to the inner circumferential side of the group so as to be in close contact with the inner circumferential surface of each magnet 12.
and a presser ring 15 that is in contact with an upper flange 39 of the cover 14 that is in contact with the upper end surfaces of the case 13 and the group of magnets 12, and the winding crimping margin 19 of the yoke 11 is A rotor for a magnet generator, characterized in that the rotor is wound radially inward and pressed onto a retainer ring 15. 2. A step of manufacturing the yoke 11 which is formed into a bowl shape and has a winding margin 19 formed at its upper end, and a partition wall is formed on the upper surface of the ring 33 which is formed into a circular ring shape and is fitted into the yoke 11. The case 13 has a plurality of portions 35 arranged in the circumferential direction and protrudes at right angles, and a magnet housing chamber 31 is formed between adjacent partition wall portions 35, 35. a step of fitting the case 13 into the yoke 11; and a step of inserting a magnet 1 into each housing chamber 31 of the case 13.
2 is inserted into the housing chamber 31, and the tips of the partition walls 35 of the case 13 are expanded and plastically deformed in the circumferential direction by a press die, and each magnet 12 inserted into the accommodation chamber 31 is inserted into the adjacent partition wall. A cylindrical cover having a lower flange 38 projecting radially inward and an upper flange 39 projecting radially outward. 14 are press-fitted into a group of 12 magnets fixed to the case 13 and arranged in an annular shape, in close contact with the inward surfaces of each magnet 12; A step in which a circular ring-shaped presser ring 15 is brought into contact with the upper flange portion 39 of the cover 14, and the winding and caulking portion 19 of the yoke 11 is rolled and caulked inward and pressed onto the presser ring 15. a step in which the lower flange portion 38 of the cover 14 is attached to the cover 1;
4. A method for manufacturing a rotor for a magnet generator, comprising: a step of stretching in the press-fitting direction;