JP2010252560A - Method of molding lundell-type core for rotary electric machine, and pair of lundell-type core - Google Patents

Method of molding lundell-type core for rotary electric machine, and pair of lundell-type core Download PDF

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JP2010252560A
JP2010252560A JP2009100317A JP2009100317A JP2010252560A JP 2010252560 A JP2010252560 A JP 2010252560A JP 2009100317 A JP2009100317 A JP 2009100317A JP 2009100317 A JP2009100317 A JP 2009100317A JP 2010252560 A JP2010252560 A JP 2010252560A
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magnetic pole
claw magnetic
magnet
claw
type iron
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Hirotoshi Kato
博敏 加藤
Katsumi Kato
克美 加藤
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KATO TEKKOSHO KK
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/28—Making machine elements wheels; discs

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of molding a Lundell-type core for a rotary electric machine, wherein the permanent magnet locking section can be molded accurately by a simple processing and a magnet can be inserted from the axial end. <P>SOLUTION: The permanent magnet locking section is provided, in such a manner that when the claw magnetic poles of a pair of Lundell-type cores are meshed alternately while inverting one core, the magnet mounting surface and the flange of one of the adjoining claw magnetic poles are arranged to face the magnet mounting surface and the flange of the other claw magnetic pole, and a magnet insertion space into which a magnet can be inserted from either axial end is formed. The magnet inserted from the axial end side is locked to the magnet-locking section in the magnet insertion space. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

本発明は、周方向に隣り合う爪磁極間に挿入された永久磁石を係止するための手段を備えた回転電機用ランデル型鉄心の成形方法およびこの方法によって形成されたランデル型鉄心を組み合わせた一対のランデル型鉄心に関する。   The present invention combines a method for forming a Randell type iron core for a rotating electrical machine having means for locking a permanent magnet inserted between claw magnetic poles adjacent to each other in the circumferential direction, and a Randel type iron core formed by this method. The present invention relates to a pair of Rundel type iron cores.

車両用交流発電機では、一対のランデル型鉄心の爪磁極間に永久磁石を装着して、その爪磁極間の漏洩磁束を減らすことによって発電に寄与する有効磁束を増加させることが一般に広く採用されている。   In vehicle alternators, it is generally widely used to increase the effective magnetic flux that contributes to power generation by mounting a permanent magnet between the claw magnetic poles of a pair of Randell type iron cores and reducing the leakage magnetic flux between the claw magnetic poles. ing.

そして、その永久磁石がランデル型鉄心の回転に伴って爪磁極から飛び出さないように爪磁極の周方向両側面外周部に磁石係止部を形成するのが一般的で、その係止部(つば部)は爪磁極の長手方向全体にわたって設けられることが特許文献１に記載されている。   And it is common to form a magnet locking part on the outer peripheral part of the both sides in the circumferential direction of the claw magnetic pole so that the permanent magnet does not jump out of the claw magnetic pole with the rotation of the Landel type iron core. Patent Document 1 describes that the collar portion is provided over the entire length of the claw magnetic pole.

一方、この種ランデル型鉄心の爪磁極の周方向両側面外周部に係止部を形成する手法としては機械切削することも考えられるが、本件出願人は、先に特許文献２に記載されているように鍛造技術を利用した製造技術を提案している。この鍛造技術は製造工程中に性格の異なる機械切削加工を施さなくとも精度の高い製品が得られる工夫がされており、その図９に示すように爪磁極の周縁部につば部を形成するものとしている。   On the other hand, as a method of forming the locking portions on the outer circumferential portions on both sides in the circumferential direction of the claw magnetic poles of this kind of Landel type iron core, it is conceivable to perform machine cutting. However, the applicant has been described in Patent Document 2 previously. As you can see, we are proposing manufacturing technology using forging technology. This forging technique has been devised so that a highly accurate product can be obtained without performing mechanical cutting with different characteristics during the manufacturing process. As shown in FIG. 9, a flange is formed on the peripheral edge of the claw pole. It is said.

特許第３７７４９８７号公報Japanese Patent No. 3774987 特許第３６０９７４５号公報Japanese Patent No. 3609745

一対のランデル型鉄心の隣り合う爪磁極間に永久磁石を容易に挿入でき、組み立て作業を容易にすることが求められるに至った。特許文献２に示す製造技術によれば、機械切削加工を施さなくとも精度の高い磁石係止部を持つ製品を提供することができるが、一対のランデル型鉄心の隣り合う爪磁極間に永久磁石を軸方向から挿入配置しようとしても爪磁極と中央部にある中央ボス部との連結部に形成される屈曲部が障害となって永久磁石の軸方向挿入ができない。この例の場合、予め磁石を設置しておいて、後に一対のランデル型鉄心を側方から磁石に嵌め込んでいくことになる。   It has been demanded that a permanent magnet can be easily inserted between adjacent claw magnetic poles of a pair of Randell type iron cores to facilitate assembly work. According to the manufacturing technique shown in Patent Document 2, it is possible to provide a product having a high-precision magnet locking portion without performing mechanical cutting, but a permanent magnet between adjacent claw magnetic poles of a pair of Landel-type iron cores. Even if an attempt is made to insert and arrange from the axial direction, the bent portion formed at the connecting portion between the claw magnetic pole and the central boss portion at the center becomes an obstacle, and the permanent magnet cannot be inserted in the axial direction. In the case of this example, a magnet is installed in advance, and a pair of Randel iron cores are fitted into the magnet from the side later.

本発明の目的は、かかる点に鑑みて鍛造による磁石係止部を可能にして単純な加工で精度良くして成形でき、磁石を軸方向端部から挿入可能として組み立て作業を容易にした回転電機用ランデル型鉄心の成形方法および一対のランデル提供しようとするものである。   SUMMARY OF THE INVENTION An object of the present invention is to provide a rotating electrical machine that allows a magnet locking part by forging to be formed with high accuracy by simple processing and facilitates assembly work by allowing a magnet to be inserted from an axial end. The present invention intends to provide a method for forming a Landell type iron core for use and a pair of Landell.

本発明は、爪磁極部の周方向両側面内周部に挿入された磁石を係止する磁石係止部を備えたランデル型鉄心の成形方法であって、
前記ランデル型鉄心は、ブランクを熱間鍛造にて荒打ちし、垂直に延伸する複数個の爪磁極部と中央ボス部を同一方向に向けて、かつ中央ボス部の外周円で爪磁極部を一体とした形状で一次爪磁極成形品を成形する工程と、該一次爪磁極成形品について中央ボス部の中心部にポンチングにて中心穴を形成すると共に、外周部をサイジングして二次爪磁極成形品を成形する工程と、該二次爪磁極成形品についての爪磁極部の内外周部及び中央ボス部を覆い、爪磁極部の内周縁部との間に爪磁極部の上下端に至る成形空間を形成して二次爪磁極成形品を保持する下金型に上金型を装着して、押圧し、冷間鍛造にて爪磁極側面に、爪極部の軸方向上下端に至る平滑な磁石載置面、および爪磁極内周縁部に、該爪磁極内周縁部の周縁部から円周方向に延び、かつ爪磁極部の軸方向上下端に至り、前記平滑な磁石載置面に連なるつば部を有する三次爪磁極成形品を成形する工程と、前記工程実施の際に型割位置に生じるバリを除去して爪磁極完成品とする工程を経て形成されることを特徴としたランデル型鉄心の成形方法を提供する。 The present invention is a method for forming a Landel type iron core provided with a magnet locking portion for locking a magnet inserted in the inner circumferential portion of both circumferential side surfaces of a claw magnetic pole portion,
The Randell type iron core is formed by roughly forging a blank by hot forging, directing a plurality of vertically extending claw magnetic pole portions and a central boss portion in the same direction, and an outer peripheral circle of the central boss portion. Forming the primary claw magnetic pole molded product in an integrated shape, and forming a central hole by punching in the center of the central boss portion of the primary claw magnetic pole molded product, and sizing the outer peripheral portion to secondary claw magnetic pole Covering the inner and outer peripheral portions and the central boss portion of the claw magnetic pole portion of the molded product, and the secondary claw magnetic pole molded product, and reaching the upper and lower ends of the claw magnetic pole portion between the inner peripheral edge portion of the claw magnetic pole portion Attach the upper die to the lower die that forms the forming space and hold the secondary claw pole molded product, press it, and reach the side of the claw pole by cold forging to the upper and lower ends in the axial direction of the claw pole part A smooth magnet mounting surface and a claw magnetic pole inner peripheral edge, and a circumferential direction from the peripheral edge of the claw magnetic pole inner peripheral edge. And a step of forming a tertiary claw magnetic pole molded product having a collar portion that reaches the upper and lower ends in the axial direction of the claw magnetic pole portion and continues to the smooth magnet mounting surface, A method for forming a Landel type iron core is provided, which is formed through a step of removing a slab to obtain a claw magnetic pole finished product.

本発明は、また、前記中央ボス部を中央ボス本体部と板状の連結部とで構成して、一次爪磁極成形品を形成し、前記型割位置Ｘを板状の連結部の板厚の外側面を基準にして、１／２以下に設定したことを特徴とするランデル型鉄心の成形方法を提供する。   In the present invention, the central boss portion is composed of a central boss main body portion and a plate-like connecting portion to form a primary claw magnetic pole molded product, and the mold dividing position X is set to the plate thickness of the plate-like connecting portion. A method for forming a Landel-type iron core is provided, which is set to 1/2 or less with respect to the outer surface of the core.

本発明は、また、爪磁極部の根本端部に内側に傾斜した、稜線部位を有する回転バランス取り用切削面を形成し、前記型割位置Ｘを回転バランス取り用切削面の稜線部位より内側に設定したことを特徴とするランデル型鉄心の成形方法を提供する。   The present invention also forms a rotation balancing cutting surface having a ridge portion inclined inwardly at the root end portion of the claw magnetic pole portion, and the mold split position X is located inside the ridge line portion of the rotation balancing cutting surface. A method for forming a Landell-type iron core is provided.

本発明は、外周から軸方向に延びて交互に噛み合うようにされた爪磁極部および爪磁極部に一体化された中央ボス部をそれぞれ備えたランデル型鉄心を組み合わせた一対のランデル型鉄心において、
各ランデル型鉄心が、爪磁極側面に、爪極部軸方向上下端に至る平滑な磁石載置面、および爪磁極内周縁部に、該爪磁極内縁部の内周縁部から内周方向に伸び、かつ爪磁極部の軸方向上下端に至り、前記平滑な磁石載置面に連なるつば部を備えた磁石係止部を有し、
一対のランデル型鉄心が一方を倒置して爪磁極部が交互に噛み合わされたときに、隣接する爪磁極部が一方の磁石載置面とつば部が他方の磁石載置面とつば部に対向配置されることによって、双方の磁石係止部が対向配置されて、磁石が軸方向のいずれかの端からも挿入することを可能にした磁石挿入空間部が形成され、該磁石挿入空間部に挿入された磁石が対向配置の磁石係止部に係止されること
を特徴とする一対のランデル型鉄心を提供する。 The present invention is a pair of Randel type iron cores combining a claw magnetic pole portion extending in the axial direction from the outer periphery and a center boss portion integrated with the claw magnetic pole portion, and a Randell type iron core each having a central boss portion.
Each Landel type iron core extends from the inner peripheral edge of the claw magnetic pole inner edge to the inner peripheral direction on the claw magnetic pole side surface, the smooth magnet mounting surface reaching the upper and lower ends of the claw pole axial direction, and the claw magnetic pole inner peripheral edge. And it has a magnet locking part provided with a collar part that reaches the upper and lower ends in the axial direction of the claw magnetic pole part and continues to the smooth magnet mounting surface,
When a pair of Landel-type iron cores are turned over and the claw magnetic pole portions are alternately meshed, the adjacent claw magnetic pole portions are opposed to one magnet placement surface and the collar portion, and the other magnet placement surface and the collar portion. By being arranged, both magnet locking portions are arranged to face each other, so that a magnet insertion space portion that allows a magnet to be inserted from either end in the axial direction is formed. A pair of Landel-type iron cores are provided, in which the inserted magnets are locked to opposing magnet locking portions.

本発明は、また、前記一対のランデル型鉄心を備えることを特徴とする車両用交流発電機の回転子を提供する。   The present invention also provides a vehicular AC generator rotor comprising the pair of Randell type iron cores.

本発明によれば、爪磁極部の軸方向上下端を貫通する磁石挿入空間部が形成され、磁石を軸方向のいずれの方向からも挿入可能となって一対のランデル型鉄心の爪磁極を交互に噛み合わせ組み立てた時に、磁石を軸方向から容易に挿入することのできる回転電機用回転子に用いるランデル型鉄心の成形方法並びにこの方法によって成形されたランデム鉄心を組み立てた時に磁石を軸方向から磁石係止部に容易に装着することができる一対のランデム鉄心を提供することができる。   According to the present invention, the magnet insertion space that penetrates the upper and lower ends in the axial direction of the claw magnetic pole portion is formed, and the magnet can be inserted from any direction in the axial direction so that the claw magnetic poles of the pair of Randell type iron cores are alternately arranged. A method for forming a Randell type iron core used in a rotor for a rotating electrical machine in which a magnet can be easily inserted from the axial direction when the magnet is assembled and assembled, and a magnet is assembled from the axial direction when the Randem iron core formed by this method is assembled. A pair of randem iron cores that can be easily attached to the magnet locking portion can be provided.

また、本発明によれば、成型金型の型割位置を適正な位置に設定することにより永久磁石係止部を単純な加工にて、精度良く成形できる回転電機用ランデル型鉄心の成形方法が提供される。   In addition, according to the present invention, there is provided a method for forming a Randel type iron core for a rotating electrical machine that can accurately form a permanent magnet locking portion by simple processing by setting a mold splitting position of a molding die to an appropriate position. Provided.

本発明の実施例で用いるブランク材の正面図。The front view of the blank material used in the Example of this invention. 本発明の実施例における一次成形品の一部縦断面を含む構造図。FIG. 3 is a structural diagram including a partial longitudinal section of a primary molded product in an example of the present invention. 本発明の実施例における二次成形品の一部縦断面を含む構造図。FIG. 3 is a structural diagram including a partial longitudinal section of a secondary molded product in an example of the present invention. 本発明の実施例における冷間鍛造成形工程の実施を示す図。The figure which shows implementation of the cold forge forming process in the Example of this invention. 図４において上金型を取り除いた状態で、上方から見た平面図。The top view seen from the top in the state which removed the upper metal mold | die in FIG. 冷間鍛造工程の実施で、型割り位置に応じてバリが生成される状態を示す正面図。The front view which shows the state in which a burr | flash is produced | generated according to the parting position by implementation of a cold forging process. 図６における側面図。The side view in FIG. 本発明の実施例における三次成形品の縦断面図。The longitudinal cross-sectional view of the tertiary molded product in the Example of this invention. 図８の三次成形品を上方から見た平面図。The top view which looked at the tertiary molded article of FIG. 8 from upper direction. 組み立て状態を立体的に示す斜視図。The perspective view which shows an assembly state in three dimensions. 三次成形品を組み合わせ、これらの間に磁石を挿入することを示す図。The figure which shows combining a tertiary molded product and inserting a magnet between these.

以下本発明の実施例を図面に基づき説明する。   Embodiments of the present invention will be described below with reference to the drawings.

図１において、ブランク材１は通常丸鋼である機械構造用炭素鋼を設計仕様に基づいた寸法に切断したものである。このブランク材１を図２に示す熱間鍛造(金型成形)にて荒打ちし、一軸方向(図面上方)に複数個の爪磁極部２と爪磁極部２より背の低い中央ボス部３を後方押し出しによりそれぞれ外径部をほぼ垂直になる様に形成した概略円盤状の一次爪磁極成形品４（以下、一次成形品という）を得る。中央ボス部３は中央ボス本体部３Ａと中央ボス本体部３Ａの側方の一体化された連結部５とからなる。該一次成形品４の爪磁極部２は先行技術文献特許第３７７４９８７号（特許文献２）の図２と同様に複数個の爪磁極部が等間隔に配置され、かつ該爪磁極部２と中央ボス部３間は連結形状の連結部５によって連結されていて、爪磁極部２はその根本部から先端に向けて先細りの板状の概略断面台形状となっている。爪磁極部２の根本外周部に、内側に傾斜した傾斜面２Ｃが形成される。   In FIG. 1, a blank material 1 is obtained by cutting a carbon steel for machine structure, which is usually a round steel, into dimensions based on design specifications. This blank material 1 is roughly struck by hot forging (molding) shown in FIG. 2, and a plurality of claw magnetic pole portions 2 and a central boss portion 3 shorter than the claw magnetic pole portions 2 in a uniaxial direction (upward in the drawing). Is pushed backward to obtain a substantially disc-shaped primary claw pole molded product 4 (hereinafter referred to as a primary molded product) in which the outer diameter portions are formed to be substantially vertical. The central boss part 3 includes a central boss main body part 3A and an integrated connecting part 5 on the side of the central boss main body part 3A. The claw magnetic pole part 2 of the primary molded product 4 has a plurality of claw magnetic pole parts arranged at equal intervals in the same manner as in FIG. 2 of Japanese Patent No. 3774987 (Patent Document 2). The bosses 3 are connected by a connecting part 5 having a connecting shape, and the claw magnetic pole part 2 has a substantially plate-like cross-sectional shape that is tapered from the base part toward the tip. An inclined surface 2 </ b> C that is inclined inward is formed on the base outer peripheral portion of the claw magnetic pole portion 2.

本実施例の特許文献２に記載された構造に対する特徴は、特許文献２に記載された磁石挿入空間部が爪磁極部が中央ボス部の連結部に載置された形状とされ、上下端に軸方向に貫通された空間部が形成されていないのに対して、最終的な組み立て時に軸方向に貫通する磁石挿入空間部を形成することを意図して中央ボス部２の外周円で、すなわち連結部５の外周円で介磁極部２を一体化した形状としたことにある。従って、爪磁極部２は連結部５の上方に載置される構造ではなく、連結部５の側方に取り付けられた形状に鍛造され、上下端貫通の磁石挿入空間部（図１０）を形成しやすいものとしている。この図において、爪磁極部の下方部を根本部２Ａ、先端部２Ｂを細長な先端部と称する。なお、図において爪磁部の外方側方にある外周面２Ｄを外縁側とし、内方側方を内縁側と称し、外縁側の側方を側方外縁側（外周外縁部）と称する。内縁側、外縁側および側方外縁共円周方向に延在する。このような形状において、根本部の端部外側には内方に傾斜した傾斜面２Ｃが形成される。   The feature of the present embodiment with respect to the structure described in Patent Document 2 is that the magnet insertion space portion described in Patent Document 2 has a shape in which the claw magnetic pole portion is placed on the coupling portion of the central boss portion, Whereas the space portion penetrating in the axial direction is not formed, the outer circumferential circle of the central boss portion 2 is intended to form a magnet insertion space portion penetrating in the axial direction during final assembly, that is, The intermediate magnetic pole part 2 is integrated with the outer peripheral circle of the connecting part 5. Accordingly, the claw magnetic pole portion 2 is not structured to be placed above the connecting portion 5 but is forged into a shape attached to the side of the connecting portion 5 to form a magnet insertion space portion (FIG. 10) penetrating the upper and lower ends. It is easy to do. In this figure, the lower part of the claw magnetic pole part is referred to as a root part 2A, and the tip part 2B is referred to as an elongated tip part. In the figure, the outer peripheral surface 2D on the outer side of the claw magnetic part is referred to as the outer edge side, the inner side is referred to as the inner edge side, and the outer edge side is referred to as the side outer edge side (outer outer edge part). The inner edge side, the outer edge side, and the side outer edge extend in the circumferential direction. In such a shape, an inclined surface 2C inclined inward is formed on the outer side of the end portion of the root portion.

次に、一次成形品４はショットブラストを施した上に冷間鍛造成形加工時の成形品と金型の摩擦抵抗をなくすためのボンデ処理が施され、その後、図３に示すように上，下反転されて金型(図示せず)に配置され、前記ボス部３の中心に連結部５の反対の爪磁極側からポンチングによって回転軸装着孔となる貫通孔６を形成した二次爪磁極成形品８（以下、二次成形品という）を得る。この図において組み立てられた時の状態から２Ｄは外周面であり、２Ｅは内周面であり、２Ｄおよび２Ｅ間の平面は上下端を亘る平面２Ｌとなる。   Next, the primary molded product 4 is subjected to shot blasting and then subjected to a bond treatment for eliminating the frictional resistance between the molded product and the mold at the time of cold forging molding, and then, as shown in FIG. A secondary claw magnetic pole which is turned down and placed in a mold (not shown), and a through hole 6 serving as a rotation shaft mounting hole is formed by punching from the claw magnetic pole side opposite to the connecting portion 5 at the center of the boss portion 3. A molded product 8 (hereinafter referred to as a secondary molded product) is obtained. From the state when assembled in this figure, 2D is an outer peripheral surface, 2E is an inner peripheral surface, and the plane between 2D and 2E is a plane 2L across the upper and lower ends.

そして、前記工程では、前記ポンチングと同時に成形品の表面状態の改善と寸法の矯正を目的とした外径サイジングが施される。   And in the said process, the outer diameter sizing for the purpose of the improvement of the surface state of a molded article and the correction of a dimension is given simultaneously with the said punching.

そして、この二次成形品８は、図４，図５に示すように爪磁極部２の外周面２Dと内周面２Ｅ及び中央ボス部３の内側面５Ａが下金型Ｋ１で囲まれるようにして下金型Ｋ１内に載置される。ここで後述するように対向して組み合わされる成形品との関係で、下金型Ｋ１には爪磁極部２に後述する磁石係止部２０を構成するつば部２Ｆを形成するために、段差成形空間（図示せず、ただし、つば部２Fに対応する。）が形成してある。この段差成形空間は爪磁極部２の側方外縁側の両側に位置するように、そして爪磁極部２に上から下まで貫通する形状の空間部を形成するようにされる。このようにした配置状態で、爪磁極部２は下金型Ｋ１に保持される。この状態で上金型Ｋ２を同軸に配置下降させて中央ボス部３および爪磁極部２の外側面５Ｂを塞ぎ、爪磁極部２に加圧を加えることによって、段差成形空間に爪磁極部２の材料の一部が塑性流動されて充満し、爪磁極部２の側方外縁側の両側に円周方向にかつ上端から下端まで延在し、円周方向に伸びるつば部２Ｆ、その内側で、上述の平面２Ｌから形成された、つば部２Ｆに連なって全平面とされた磁石載置面２Ｈが形成され、その結果磁石係止部２０が形成される。このようにして、磁石係止部２０付きの三次爪磁極成型品９（以下、三次成形品という）を得る。   In the secondary molded product 8, the outer peripheral surface 2D and the inner peripheral surface 2E of the claw magnetic pole portion 2 and the inner side surface 5A of the central boss portion 3 are surrounded by the lower mold K1 as shown in FIGS. And placed in the lower mold K1. Here, in order to form a flange portion 2F constituting a magnet locking portion 20 described later on the claw magnetic pole portion 2, the lower mold K1 is formed with a step in relation to a molded product that is opposed and combined as described later. A space (not shown, but corresponding to the flange portion 2F) is formed. This step forming space is located on both sides of the claw magnetic pole portion 2 on the side outer edge side, and a space portion having a shape penetrating from the top to the bottom is formed in the claw magnetic pole portion 2. In this arrangement state, the claw magnetic pole portion 2 is held by the lower mold K1. In this state, the upper die K2 is coaxially disposed and lowered to close the central boss portion 3 and the outer surface 5B of the claw magnetic pole portion 2, and by applying pressure to the claw magnetic pole portion 2, the claw magnetic pole portion 2 is formed in the step forming space. Part of the material is filled with plastic flow, and the collar 2F extends in the circumferential direction on both sides of the claw magnetic pole part 2 from the upper end to the lower end and extends in the circumferential direction. The magnet mounting surface 2H, which is formed from the above-described plane 2L and is continuous with the collar portion 2F, is formed as a whole plane, and as a result, the magnet locking portion 20 is formed. In this way, a tertiary claw pole molded product 9 (hereinafter referred to as a tertiary molded product) with a magnet locking portion 20 is obtained.

前述したように磁石係止部２０は、冷間鍛造によって、爪磁極部２の側方外縁側の両側に、爪極部の軸方向上下端に至る平滑な磁石載置面２Ｈ、および爪磁極内縁部にこの爪磁極部の軸方向上下端に至り、平滑な磁石載置面２Ｈに連なるつば部２Ｆによって形成される。従って、つば部２Ｆ、磁石載置面２Ｈと記載した時に、爪磁極部２の両側に形成されたつば部および磁石載置面を意味することになる。ここで、前述の傾斜面２Ｃに対応して形成された傾斜面を２Ｒで表す。このようにして形成した三次成形品８の型割位置Ｘには、バリ７が上側金型側に生じる。このバリ７の処理方向について説明する。   As described above, the magnet locking portion 20 is formed by cold forging on both sides of the claw magnetic pole portion 2 on the outer side of the side, the smooth magnet placement surface 2H reaching the upper and lower ends in the axial direction of the claw pole portion, and the claw magnetic pole. The inner edge portion is formed by a flange portion 2F that reaches the upper and lower ends in the axial direction of the claw magnetic pole portion and continues to the smooth magnet mounting surface 2H. Accordingly, when the collar portion 2F and the magnet placement surface 2H are described, the collar portion and the magnet placement surface formed on both sides of the claw magnetic pole portion 2 are meant. Here, the inclined surface formed corresponding to the aforementioned inclined surface 2C is represented by 2R. At the mold split position X of the tertiary molded product 8 formed in this way, burrs 7 are generated on the upper mold side. The processing direction of the burr 7 will be described.

このようにして得られた三次成型品９は詳細を図６，図７に示すように上，下金型の型割位置Ｘが、それぞれの爪磁極部２の根本部の内周面２Ｄに形成した傾斜面２Ｒの面上（傾斜面開始点を含めて）である。   As shown in detail in FIG. 6 and FIG. 7, the tertiary molded product 9 obtained in this manner has the upper and lower mold split positions X on the inner peripheral surface 2 </ b> D of the base part of each claw magnetic pole part 2. It is on the surface of the formed inclined surface 2R (including the inclined surface start point).

形成されたプレス成型面（端部は曲面）２Ｒの稜線部位２Ｋよりも内側に来るように設定されている。型割位置Ｘの上金型側にバリ７が生じる。前述の傾斜面２Ｒは、プレス成型面とされる。稜線部２Ｋは、連結部５の外周端面が内側に向けて傾斜するその傾斜点の開始点である。このバリ７の発生位置は本発明者等が経験に基いて試作を重ね導き出したもので、上金型Ｋ２を浅くしたことによりプレス成型した加工製品である三次成形品を金型から抜き出す場合の、所謂抜き力を改善すると共に、成型時の加工圧を下げることを成功させ、型寿命延長或いは作業効率にも大きく貢献できることを確信した。   It is set so as to come inside the ridgeline part 2K of the formed press-molded surface (the end is a curved surface) 2R. A burr 7 is generated on the upper mold side of the parting position X. The aforementioned inclined surface 2R is a press-molded surface. The ridge line portion 2K is a starting point of the inclined point where the outer peripheral end surface of the connecting portion 5 is inclined inward. The position where this burr 7 is generated is the result of repeated trial production by the present inventors based on experience, and in the case where a tertiary molded product, which is a press-molded processed product by making the upper mold K2 shallow, is extracted from the mold. We have improved the so-called punching force and succeeded in lowering the processing pressure during molding, and have convinced that it can greatly contribute to the extension of mold life or work efficiency.

次に三次成型品９は、次工程の図８，図９において、冷間加工にてバリ７抜き仕上げが行われ完成品１０となる。   Next, in FIG. 8 and FIG. 9 of the next process, the tertiary molded product 9 is finished by removing burrs 7 by cold working.

前記した型割位置Ｘは、好ましくは連結部５を構成する連結板の板厚Ｔ０の外側面５Ｂを基準にして１／２以下の範囲ｔにあって、プレス成型面２Ｒ（プレス成型曲面２Ｒの稜線部位２Ｋと同位置）の稜線部位２Ｋより僅かに内側位置している。プレス成型面２Ｒは切削加工されてバランス取り用切削面となる。この回転バランス取り用切削面は一般に連結板材５の外側面５Ｂを基準にしてほぼ３０度の傾斜を持って全周が切削加工されて形成される。   The above-mentioned parting position X is preferably in a range t of ½ or less with respect to the outer surface 5B of the plate thickness T0 of the connecting plate constituting the connecting portion 5, and is press-molded surface 2R (press-molded curved surface 2R). The same position as the ridge line part 2K) is located slightly inside the ridge line part 2K. The press-molding surface 2R is cut to become a balancing cutting surface. This rotational balancing cutting surface is generally formed by cutting the entire circumference with an inclination of approximately 30 degrees with respect to the outer surface 5B of the connecting plate member 5.

三次成型品９は、図８、図９に示す次工程において冷間加工にてバリ７抜き仕上げが行われるが、前記したように型割位置Ｘが爪磁極部２の根本部の外周面２Ｄに形成されたプレス成型面２Ｒ、すなわち回転バランス取り用切削面の稜線部位２Ｋより内側に位置しているため、三次成型品９を得るための冷間鍛造時に生じるバリ７は回転バランス取り用切削面の成形時にほとんど除去される。このように、爪磁極部２の外周面２Ｄにバリ７はない。   The tertiary molded product 9 is finished by removing burrs 7 by cold working in the next process shown in FIGS. 8 and 9, but the mold split position X is the outer peripheral surface 2D of the base part of the claw magnetic pole part 2 as described above. 2B, that is, the burrs 7 generated during the cold forging to obtain the tertiary molded product 9 are the rotational balancing cuttings. Almost removed during surface molding. Thus, there is no burr 7 on the outer peripheral surface 2D of the claw magnetic pole portion 2.

この様にして成形されたランデル型鉄心は、ランデル鉄心の組み立て方法として一般に採用される、先行技術文献に挙げた特許第３７７４９８７号の図２の様に界磁巻線を挟んで回転軸の両側から組み合わされる三次成型品８の爪磁極同士が対峙するように一方が倒置されて車両用高流発電機の回転子の回転軸（図示せず）に装着される。図１０，図１１に示すように交互に配置された爪磁極２間に左右両側に形成された一対の磁石係止部２０が位置する。この磁石係止部２０には左右いずれかの方向から予め着磁され、もしくは装着後に着磁される磁石体１１が挿入され界磁極を構成する。   The Rundel-type iron core formed in this way is generally used as a method for assembling the Landell iron core. As shown in FIG. 2 of Japanese Patent No. 3774987 cited in the prior art document, both sides of the rotating shaft are sandwiched between the field windings. One is inverted so that the claw magnetic poles of the tertiary molded product 8 combined with each other face each other and mounted on the rotating shaft (not shown) of the rotor of the vehicle high-flow generator. As shown in FIGS. 10 and 11, a pair of magnet locking portions 20 formed on the left and right sides are located between the claw magnetic poles 2 arranged alternately. A magnet body 11 that is magnetized in advance from either the left or right direction or magnetized after mounting is inserted into the magnet locking portion 20 to form a field pole.

磁石１１の挿入について説明する。
図１０および図１１は以上のように構成した完成品１０を上下に対向させて組み立てる方法を示す図である。これらの図に示すように、一方の完成品１０（下側）は爪磁極部２が上側を向いて配置され、他方の完成品１０（上側）の爪磁極部２が下側を向いて配置され、一方の完成品の両隣りの爪磁極部間に他方の完成品１０の１つの爪磁極部２が位置するように配設される。この配設によって磁石係止部２０が対向設定され、この間に磁石挿入空間３０が形成される。なお、図１１において磁石１１が挿入状態を明確にするために実線で示してあるが、配置状態では内側になるので実際は点線表示となる。 The insertion of the magnet 11 will be described.
10 and 11 are diagrams showing a method of assembling the finished product 10 configured as described above so as to face each other vertically. As shown in these drawings, one finished product 10 (lower side) is arranged with the claw magnetic pole part 2 facing upward, and the other finished product 10 (upper) with the claw magnetic pole part 2 facing downward. Then, one claw magnetic pole part 2 of the other finished product 10 is disposed between the claw magnetic pole parts adjacent to one finished product. By this arrangement, the magnet locking portion 20 is set oppositely, and a magnet insertion space 30 is formed therebetween. In FIG. 11, the magnet 11 is shown by a solid line for clarifying the insertion state.

この場合に、前述したように磁石係止部２０は爪磁極部２の内周部の内周縁部両側に上端から下端まで延在し、円周方向に伸びるつば部２Ｆおよび、このつば部２Ｆの内側に連なる磁石載置面２Ｈを有するように形成され、つば部２Ｆ内面の磁石押さえ面および磁石載置面２Ｈは双方の隣接するつば最上端から最下位置までそれぞれ全平面とされ、その途中に突起物などの挿入の際に挿入障害となる障害物が形成されていない。なお、つば２Ｆは回転バランス切削面２Ｒが形成してあるためにこの部分では薄厚となる。この回転バランス切削面２Ｒがない場合には、最終端部も同厚の平面となる。   In this case, as described above, the magnet locking portion 20 extends from the upper end to the lower end on both sides of the inner peripheral portion of the inner peripheral portion of the claw magnetic pole portion 2 and extends in the circumferential direction, and the flange portion 2F. The magnet pressing surface and the magnet mounting surface 2H on the inner surface of the collar portion 2F are all flat surfaces from the uppermost end to the lowermost position of both adjacent collars, There are no obstacles that can cause an insertion failure when inserting protrusions. The collar 2F is thin at this portion because the rotation balance cutting surface 2R is formed. When there is no rotation balance cutting surface 2R, the final end is also a flat surface having the same thickness.

従って、上下に２つの完成品１０を組み合わせると、双方の隣接するつば部２Ｆはそれぞれの爪磁極部２の上から下までの間で、また磁石載置面２Ｈはそれぞれの爪磁極部の上から下までの間で平面状に対向する。この結果、２つの磁石係止部２０間には上からもしくは下からの方向から一定の厚さの板状の磁石１１を挿入し得る磁石挿入空間部３０が形成されることになる。この磁石挿入空間部３０の挿入方向に対する直角方向の幅は望ましくは等幅である。   Therefore, when the two finished products 10 are combined vertically, both adjacent collar portions 2F are between the top and bottom of each claw magnetic pole portion 2, and the magnet mounting surface 2H is above each claw magnetic pole portion. It faces in a planar shape from the bottom to the bottom. As a result, a magnet insertion space 30 into which the plate-like magnet 11 having a certain thickness can be inserted from above or from the bottom is formed between the two magnet locking portions 20. The width of the magnet insertion space 30 in the direction perpendicular to the insertion direction is preferably equal.

すなわち、磁石係止部２０は、磁石１１が一方の端部（例えば上側端部）から挿入されて他方の端部（例えば下側端部）から挿出されることが可能とする磁石挿入空間部３０を備え、この磁石挿入空間部１２に軸方向端側から挿入された磁石１１が係止される。   In other words, the magnet locking portion 20 has a magnet insertion space portion that allows the magnet 11 to be inserted from one end (for example, the upper end) and to be inserted from the other end (for example, the lower end). The magnet 11 inserted from the axial direction end side is locked in the magnet insertion space 12.

このようにして構成した一対のランデル型鉄心は、車両用交流発電機の回転子に望ましく適用される。   The pair of Randel type iron cores configured as described above is desirably applied to a rotor of an automotive alternator.

２…爪磁極部、３…中央ボス部、４…一次成形品、５…連結部、２Ａ…爪磁極部２の根本部、２Ｂ…爪磁極部２の先端部、２Ｃ…傾斜面、２Ｄ…外周面、２Ｅ…内周面、２Ｋ…プレス成型面２Ｒの稜線部位、２Ｆ…つば部、２Ｈ…磁石載置面、２Ｌ…外周部、２Ｒ…プレス成形面，回転バランス取り用切削面、５Ａ…中央ボス部３の内側面、７…バリ、８…二次爪磁極成形品（二次成形品）、９…三次爪磁極成形品（三次成形品）、１０…完成品、１１…磁石、２０…磁石係止部、３０…磁石挿入空間部、Ｋ１…下金型、Ｋ２…上金型、Ｘ…上，下金型の型割位置。   2 ... Claw magnetic pole part, 3 ... Central boss part, 4 ... Primary molded product, 5 ... Connection part, 2A ... Base part of claw magnetic pole part 2, 2B ... Tip part of claw magnetic pole part 2, 2C ... Inclined surface, 2D ... Outer peripheral surface, 2E ... inner peripheral surface, 2K ... ridge line part of press molding surface 2R, 2F ... collar, 2H ... magnet mounting surface, 2L ... outer peripheral portion, 2R ... press molding surface, cutting surface for rotational balancing, 5A ... inner surface of central boss part 3, 7 ... burr, 8 ... secondary claw pole molded product (secondary molded product), 9 ... tertiary claw pole molded product (tertiary molded product), 10 ... finished product, 11 ... magnet, 20 ... Magnet locking part, 30 ... Magnet insertion space part, K1 ... Lower mold, K2 ... Upper mold, X ... Split position of upper and lower molds.

Claims (5)

爪磁極部の周方向両側面内周部に挿入された磁石を係止する磁石係止部を備えたランデル型鉄心の成形方法であって、
前記ランデル型鉄心は、ブランクを熱間鍛造にて荒打ちし、垂直に延伸する複数個の爪磁極部と中央ボス部を同一方向に向けて、かつ中央ボス部の外周円で爪磁極部を一体とした形状で一次爪磁極成形品を成形する工程と、該一次爪磁極成形品について中央ボス部の中心部にポンチングにて中心穴を形成すると共に、外周部をサイジングして二次爪磁極成形品を成形する工程と、該二次爪磁極成形品についての爪磁極部の内外周部及び中央ボス部を覆い、爪磁極部の内周縁部との間に爪磁極部の上下端に至る成形空間を形成して二次爪磁極成形品を保持する下金型に上金型を装着して、押圧し、冷間鍛造にて爪磁極側面に、爪極部の軸方向上下端に至る平滑な磁石載置面、および爪磁極内周縁部に、該爪磁極内周縁部の周縁部から円周方向に延び、かつ爪磁極部の軸方向上下端に至り、前記平滑な磁石載置面に連なるつば部を有する三次爪磁極成形品を成形する工程と、前記工程実施の際に型割位置に生じるバリを除去して爪磁極完成品とする工程を経て形成されることを特徴としたランデル型鉄心の成形方法。 A method for forming a Landell-type iron core having a magnet locking portion for locking a magnet inserted in the inner peripheral portion of both circumferential side surfaces of a claw magnetic pole portion,
The Randell type iron core is formed by roughly forging a blank by hot forging, directing a plurality of vertically extending claw magnetic pole portions and a central boss portion in the same direction, and an outer peripheral circle of the central boss portion. Forming the primary claw magnetic pole molded product in an integrated shape, and forming a central hole by punching in the center of the central boss portion of the primary claw magnetic pole molded product, and sizing the outer peripheral portion to secondary claw magnetic pole Covering the inner and outer peripheral portions and the central boss portion of the claw magnetic pole portion of the molded product, and the secondary claw magnetic pole molded product, and reaching the upper and lower ends of the claw magnetic pole portion between the inner peripheral edge portion of the claw magnetic pole portion Attach the upper die to the lower die that forms the forming space and hold the secondary claw pole molded product, press it, and reach the side of the claw pole by cold forging to the upper and lower ends in the axial direction of the claw pole part A smooth magnet mounting surface and a claw magnetic pole inner peripheral edge, and a circumferential direction from the peripheral edge of the claw magnetic pole inner peripheral edge. And a step of forming a tertiary claw magnetic pole molded product having a collar portion that reaches the upper and lower ends in the axial direction of the claw magnetic pole portion and continues to the smooth magnet mounting surface, A method for forming a Landel type iron core, which is formed through a process of removing a slab to obtain a claw magnetic pole finished product. 請求項１記載において、前記中央ボス部を中央ボス本体部と板状の連結部とで構成して、一次爪磁極成形品を形成し、前記型割位置Ｘを板状の連結部の板厚の外側面を基準にして、１／２以下に設定したことを特徴とするランデル型鉄心の成形方法。   2. The center boss portion according to claim 1, comprising a central boss main body portion and a plate-like connecting portion to form a primary claw magnetic pole molded product, and the mold dividing position X is defined as a plate thickness of the plate-like connecting portion. A method of forming a Landel type iron core, characterized in that it is set to 1/2 or less with respect to the outer surface of the core. 請求項２記載において、爪磁極部の根本端部に内側に傾斜した、稜線部位を有する回転バランス取り用切削面を形成し、前記型割位置Ｘを回転バランス取り用切削面の稜線部位より内側に設定したことを特徴とするランデル型鉄心の成形方法。   3. The rotary balancing cutting surface having a ridge line portion, which is inclined inwardly at a root end portion of the claw magnetic pole portion, is formed, and the mold dividing position X is located on the inner side of the ridge line portion of the rotational balancing cutting surface. A method for forming a Randell type iron core, characterized in that it is set to. 外周から軸方向に延びて交互に噛み合うようにされた爪磁極部および爪磁極部に一体化された中央ボス部をそれぞれ備えたランデル型鉄心を組み合わせた一対のランデル型鉄心において、
各ランデル型鉄心が、爪磁極側面に、爪極部軸方向上下端に至る平滑な磁石載置面、および爪磁極内周縁部に、該爪磁極内縁部の内周縁部から内周方向に伸び、かつ爪磁極部の軸方向上下端に至り、前記平滑な磁石載置面に連なるつば部を備えた磁石係止部を有し、
一対のランデル型鉄心が一方を倒置して爪磁極部が交互に噛み合わされたときに、隣接する爪磁極部が一方の磁石載置面とつば部が他方の磁石載置面とつば部に対向配置されることによって、双方の磁石係止部が対向配置されて、磁石が軸方向のいずれかの端からも挿入することを可能にした磁石挿入空間部が形成され、該磁石挿入空間部に挿入された磁石が対向配置の磁石係止部に係止されること
を特徴とする一対のランデル型鉄心。 In a pair of Randell type iron cores that combine a claw magnetic pole portion that extends in the axial direction from the outer periphery and a central boss portion that is integrated with the claw magnetic pole portion, respectively,
Each Landel type iron core extends from the inner peripheral edge of the claw magnetic pole inner edge to the inner peripheral direction on the claw magnetic pole side surface, the smooth magnet mounting surface reaching the upper and lower ends of the claw pole axial direction, and the claw magnetic pole inner peripheral edge. And it has a magnet locking part provided with a collar part that reaches the upper and lower ends in the axial direction of the claw magnetic pole part and continues to the smooth magnet mounting surface,
When a pair of Landel-type iron cores are turned over and the claw magnetic pole portions are alternately meshed, the adjacent claw magnetic pole portions are opposed to one magnet placement surface and the collar portion, and the other magnet placement surface and the collar portion. By being arranged, both magnet locking portions are arranged to face each other, so that a magnet insertion space portion that allows a magnet to be inserted from either end in the axial direction is formed. A pair of Landel type iron cores, wherein the inserted magnets are locked to the opposing magnet locking portions. 請求項４に記載した一対のランデル型鉄心を備えることを特徴とする車両用交流発電機の回転子。   A rotor for a vehicle alternator comprising the pair of Landel type iron cores according to claim 4.
JP2009100317A 2009-04-16 2009-04-16 Method of molding lundell-type core for rotary electric machine, and pair of lundell-type core Pending JP2010252560A (en)

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