JP2013211982A - Rotor and motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor that reduces the parts count.SOLUTION: A rotor has first rear magnets 41 and second rear magnets 42 arranged in respective gaps created at the rears 22c and 32c of first claw-like magnetic poles 22 and second claw-like magnetic poles 32. The first rear magnets 41 and the second rear magnets 42 are molded integrally with a first rotor core 20 and a second rotor core 30, respectively.

Description

  The present invention relates to a rotor and a motor.

  The rotor used in the motor has a pair of rotor cores that are combined with each other having a plurality of claw-shaped magnetic poles in the circumferential direction, and each claw-shaped magnetic pole is alternately different by arranging a field magnet between them. There is a so-called Landel-type rotor that functions as a magnetic pole (see, for example, Patent Document 1).

Japanese Utility Model Publication No. 5-43749

By the way, this type of rotor has a problem that the number of parts tends to increase, and the number of assembly steps increases accordingly.
The present invention has been made to solve the above-described problems, and an object thereof is to provide a rotor and a motor that can suppress the number of parts.

  In order to solve the above-mentioned problem, the invention according to claim 1 is characterized in that a plurality of first claw-shaped magnetic poles are projected radially outward at equal intervals on the outer periphery of the substantially disk-shaped first core base. A plurality of second claw-shaped magnetic poles protrude outward in the radial direction and extend in the axial direction at equal intervals on the outer periphery of the first rotor core extending in the direction and the substantially disk-shaped second core base. A second rotor core disposed between the first claw-shaped magnetic poles of the first rotor core to which each of the second claw-shaped magnetic poles corresponds, and the axial direction between the first core base and the second core base. A field magnet that is disposed between and magnetized in the axial direction so that the first claw-shaped magnetic pole functions as a first magnetic pole and the second claw-shaped magnetic pole functions as a second magnetic pole; The gap generated on the back surface of the claw-shaped magnetic pole, and the first claw-shaped magnetic pole in the circumferential direction and the And an auxiliary magnet disposed on at least one of the gap between the second claw-shaped magnetic poles, said auxiliary magnet is characterized in that it is at least one integrally molded of the first and second rotor core.

  In the present invention, the auxiliary magnet disposed in at least one of the gap formed on the back surface of each claw-shaped magnetic pole and the gap between each claw-shaped magnetic pole in the circumferential direction is an integral part with at least one of the first and second rotor cores. The Thereby, compared with the structure by which each rotor core, the field magnet, and the auxiliary magnet were made into the different bodies, the number of parts can be suppressed. Moreover, it leads to suppressing the assembly man-hour of a part, and it can contribute to the reduction of the assembly cost of a part by extension. Furthermore, it can be set as the structure which magnetic flux does not leak easily from the clearance gap between rotors with an auxiliary magnet.

  According to a second aspect of the present invention, in the rotor according to the first aspect, the auxiliary magnet includes a first back magnet disposed in a gap generated on a back surface of the first claw-shaped magnetic pole, and the second claw-shaped magnetic pole. A second back magnet disposed in a gap formed on the back surface of the first back magnet, wherein the first back magnet is formed integrally with the first rotor core, and the second back magnet is formed integrally with the second rotor core. It is characterized by being.

In the present invention, the number of parts can be reduced while suppressing the leakage magnetic flux from the gap generated on the back surface of each claw-shaped magnetic pole by each back magnet.
According to a third aspect of the present invention, in the rotor according to the first or second aspect, the auxiliary magnet is integrally formed with each of the rotor core and the field magnet.

In this invention, since each rotor core, a field magnet, and an auxiliary magnet are made into an integral part, it can be set as a structure with few parts.
According to a fourth aspect of the present invention, a plurality of first claw-shaped magnetic poles are formed on the outer periphery of the substantially disk-shaped first core base so that the first claw-shaped magnetic poles protrude radially outward and extend in the axial direction. A plurality of second claw-shaped magnetic poles project radially outward and extend in the axial direction on the outer peripheral portion of one rotor core and a substantially disc-shaped second core base, and extend in the axial direction. The magnetic poles are disposed between the first claw-shaped magnetic poles of the corresponding first rotor core and the axial direction between the first core base and the second core base. And a field magnet that causes the first claw-shaped magnetic pole to function as a first magnetic pole and the second claw-shaped magnetic pole to function as a second magnetic pole by being magnetized. It is formed integrally with at least one of the first and second rotor cores.

  In this invention, since at least one of the first and second rotor cores and the field magnet are integrated, the number of parts can be reduced as compared with a configuration in which each rotor core and field magnet are all separated. . Moreover, it leads to suppressing the assembly man-hour of a part, and it can contribute to the reduction of the assembly cost of a part by extension.

According to a fifth aspect of the present invention, in the rotor according to any one of the first to fourth aspects, each of the rotor cores is configured by a dust core.
In this invention, since each rotor core is comprised with a powder magnetic core, it becomes possible to compression-mold each rotor core with an auxiliary magnet (or field magnet). Thereby, it can contribute to simplification of manufacture.

A sixth aspect of the present invention is a motor including the rotor according to any one of the first to fifth aspects.
In the present invention, a motor with a reduced number of parts can be provided.

  Therefore, according to the above-described invention, the number of parts can be suppressed.

Sectional drawing of the motor of 1st Embodiment. The top view of the motor of the same form. The perspective view of the rotor of the same form. Sectional drawing of the rotor of the same form. The disassembled perspective view of the rotor of the same form. (A)-(d) The schematic diagram for demonstrating the manufacturing method of the rotor of the same form. (A)-(d) The schematic diagram for demonstrating the manufacturing method of the rotor of another example. The perspective view of the rotor of 2nd Embodiment. (A)-(d) The schematic diagram for demonstrating the manufacturing method of the rotor of the same form. The perspective view of the rotor of another example.

(First embodiment)
A first embodiment of the present invention will be described below with reference to the drawings.
As shown in FIGS. 1 and 2, a motor case 2 of a motor 1 includes a cylindrical housing 3 formed in a bottomed cylindrical shape, and an opening on the front side (left side in FIG. 1) of the cylindrical housing 3. And a front end plate 4 for closing. A circuit housing box 5 that houses a power supply circuit such as a circuit board is attached to an end of the cylindrical housing 3 on the rear side (right side in FIG. 1). A stator 6 is fixed to the inner peripheral surface of the cylindrical housing 3. The stator 6 includes an armature core 7 having a plurality of teeth extending radially inward, and a segment conductor (SC) winding 8 wound around the teeth of the armature core 7. The rotor 11 of the motor 1 has a rotating shaft 12 and is disposed inside the stator 6. The rotary shaft 12 is a columnar metal shaft made of a magnetic material, and is rotatably supported by bearings 13 and 14 supported by the bottom 3 a of the cylindrical housing 3 and the front end plate 4.

  As shown in FIGS. 3, 4, and 5, the rotor 11 includes a rotating shaft 12, a first rotor core 20, a second rotor core 30, an annular magnet 40 as a field magnet, and a first as an auxiliary magnet. And second back magnets 41 and 42.

  The first rotor core 20 has a substantially disk-shaped first core base 21. An insertion hole 21c through which the rotary shaft 12 is inserted is formed in the central portion of the first core base 21 in the axial direction. The rotary shaft 12 is press-fitted and fixed in the insertion hole 21c. Thereby, the 1st rotor core 20 and the rotating shaft 12 can rotate integrally.

  A plurality of (five in the present embodiment) first claw-shaped magnetic poles 22 project outward in the radial direction and extend in the axial direction on the outer peripheral portion of the first core base 21 at equal intervals. The circumferential end surfaces 22a and 22b of the first claw-shaped magnetic pole 22 are flat surfaces extending in the radial direction (not inclined with respect to the radial direction when viewed from the axial direction), and the first claw-shaped magnetic pole 22 has a cross section in the direction perpendicular to the axis. Has a fan shape. The circumferential angle of each first claw-shaped magnetic pole 22, that is, the angle between the circumferential end faces 22 a and 22 b is set smaller than the angle of the gap between the first claw-shaped magnetic poles 22 adjacent in the circumferential direction.

  A first back magnet 41 is provided on the back surface 22 c (radially inner surface) of each first claw-shaped magnetic pole 22. The first back magnet 41 is integrally formed with each first claw-shaped magnetic pole 22 of the first rotor core 20 by insert molding. That is, the 1st rotor core 20 and each 1st back magnet 41 are comprised as an integral component (refer FIG. 5). The first back magnet 41 is integrally formed with the first claw-shaped magnetic pole 22 so as to be in close contact with the back surface 22 c of the first claw-shaped magnetic pole 22 in the radial direction, and the radially extending portion of the first claw-shaped magnetic pole 22. 22d (a portion extending in the radial direction from the first core base 21) is in close contact with the axial direction (see FIG. 4). The first back magnet 41 has a fan-shaped cross section in the direction perpendicular to the axis, and both end surfaces in the circumferential direction are formed in a planar shape that is flush with the circumferential end surfaces 22a and 22b of the first claw-shaped magnetic pole 22, respectively. Yes. Further, the front end surface 41a in the axial direction of the first back magnet 41 (the end surface opposite to the radially extending portion 22d side) is formed to be flush with the front end surface 22e of the first claw-shaped magnetic pole 22. Yes.

  As shown in FIGS. 4 and 5, the second rotor core 30 has the same shape as the first rotor core 20, and the rotation shaft 12 is inserted through the central portion of the substantially disk-shaped second core base 31. A hole 31c is formed. The rotary shaft 12 is press-fitted and fixed in the insertion hole 31c. Thereby, the 2nd rotor core 30 and the rotating shaft 12 can rotate integrally.

  A plurality of second claw-shaped magnetic poles 32 project outward in the radial direction and extend in the axial direction on the outer peripheral portion of the second core base 31 at equal intervals. The circumferential end surfaces 32a and 32b of the second claw-shaped magnetic pole 32 are flat surfaces extending in the radial direction, and the second claw-shaped magnetic pole 32 has a fan-shaped cross section in the direction perpendicular to the axis. The circumferential angle of each second claw-shaped magnetic pole 32, that is, the angle between the circumferential end faces 32a and 32b is set smaller than the angle of the gap between the second claw-shaped magnetic poles 32 adjacent in the circumferential direction.

  Further, a second back magnet 42 is provided on the back surface 32 c (radially inner surface) of each second claw-shaped magnetic pole 32. The second back magnet 42 is integrally formed with each second claw-shaped magnetic pole 32 of the second rotor core 30 by insert molding. That is, the 2nd rotor core 30 and each 2nd back magnet 42 are comprised as an integral component (refer FIG. 5). The second back magnet 42 is integrally formed with the second claw-shaped magnetic pole 32 so as to be in close contact with the back surface 32 c of the second claw-shaped magnetic pole 32 in the radial direction, and the radially extending portion of the second claw-shaped magnetic pole 32. 32d (a portion extending in the radial direction from the second core base 31) is in close contact with the axial direction (see FIG. 4). This second back magnet 42 has a fan-shaped cross section in the direction perpendicular to the axis, and both end surfaces in the circumferential direction are formed in a planar shape that is flush with the circumferential end surfaces 32a, 32b of the second claw-shaped magnetic pole 32, respectively. Yes. Further, the tip end surface 42a in the axial direction of the second back magnet 42 (the end surface opposite to the radially extending portion 32d side) is formed to be flush with the tip surface 32e of the second claw-shaped magnetic pole 32. Yes.

  The second rotor core 30 is assembled to the first rotor core 20 such that each second claw-shaped magnetic pole 32 is disposed between each corresponding first claw-shaped magnetic pole 22. Specifically, one circumferential end surface 22a of the first claw-shaped magnetic pole 22 and the other circumferential end surface 32b of the second claw-shaped magnetic pole 32 are formed so as to be parallel along the axial direction. The gap between the end faces 22a and 32b is formed so as to be substantially linear along the axial direction. Similarly, the other circumferential end face 22b of the first claw-shaped magnetic pole 22 and one circumferential end face 32a of the second claw-shaped magnetic pole 32 are formed so as to be parallel along the axial direction. The gap between the end faces 22b and 32a is formed so as to be substantially linear along the axial direction.

  The radially inner side surface 41 b of the first back magnet 41 integrally formed with the first claw-shaped magnetic pole 22 is in contact with the outer circumferential surface 31 d of the second core base 31 in the radial direction. Similarly, the radially inner side surface 41 b of the second back magnet 42 formed integrally with the second claw-shaped magnetic pole 32 is in contact with the outer circumferential surface 21 d of the first core base 21 in the radial direction. That is, the first back magnet 41 is interposed between the second core base 31 and the first claw-shaped magnetic pole 22 in the radial direction, and the second back magnet 42 is connected to the first core base 21 and the second claw in the radial direction. It is interposed between the magnetic poles 32. The front end surface 22e of the first claw-shaped magnetic pole 22 and the front end surface 41a in the axial direction of the first back magnet 41 are configured to be flush with the axial end surface 31b in the axial direction of the second core base 31. Similarly, the tip end face 32e of the second claw-shaped magnetic pole 32 and the tip end face 42a in the axial direction of the second back magnet 42 are configured to be flush with the axially outer end face 21b of the first core base 21. .

  An annular magnet 40 is disposed (clamped) between the first core base 21 and the second core base 31 in the axial direction. The annular magnet 40 has an annular shape, and the rotation shaft 12 passes through the center portion thereof. The annular magnet 40 is in close contact with the axially inner end surface 21 a of the first core base 21 and the axially inner end surface 31 a of the second core base 31. The axially inner end surfaces 21 a and 31 a of the core bases 21 and 31 and the axially opposite end surfaces of the annular magnet 40 have a planar shape perpendicular to the axis of the rotary shaft 12. Further, the outer peripheral surface of the annular magnet 40 is in contact with the radially inner side surfaces 41b and 42b of the first and second back magnets 41 and 42 in the radial direction. That is, the first back magnet 41 is interposed between the annular magnet 40 and the first claw-shaped magnetic pole 22 in the radial direction, and the second back magnet 42 includes the annular magnet 40 and the second claw-shaped magnetic pole 32 in the radial direction. It is interposed between

  The annular magnet 40 causes the first claw-shaped magnetic pole 22 to function as a first magnetic pole (N pole in this embodiment), and causes the second claw-shaped magnetic pole 32 to function as a second magnetic pole (S pole in this embodiment). Thus, it is magnetized in the axial direction. Therefore, the rotor 11 of the present embodiment is a so-called Landel type rotor using the annular magnet 40 as a field magnet. In the rotor 11, first claw-shaped magnetic poles 22 that are N poles and second claw-shaped magnetic poles 32 that are S poles are alternately arranged in the circumferential direction, and the number of magnetic poles is 10 (the number of pole pairs is 5). It becomes. Here, since the number of pole pairs is an odd number of 3 or more, the claw-like magnetic poles having the same polarity do not face each other at 180 ° in the circumferential direction when viewed in the rotor core unit, so that the shape is stable against magnetic vibration.

  In addition, the first back magnet 41 has a side that comes into close contact with the first claw-shaped magnetic pole 22 (outside in the radial direction) and a side that contacts the second core base 31 with the N pole having the same polarity as the first claw-shaped magnetic pole 22 ( The radially inner side is magnetized in the radial direction so as to be the south pole of the same polarity as the second core base 31. Similarly, the second back magnet 42 has a side that comes into close contact with the second claw-shaped magnetic pole 32 (outside in the radial direction) and a side that contacts the first core base 21 with the S pole having the same polarity as the second claw-shaped magnetic pole 32. It is magnetized in the radial direction so that the (inner side in the radial direction) becomes the north pole of the same polarity as the first core base 21. The magnetic fluxes of the first and second back magnets 41 and 42 flow to the first and second claw-shaped magnetic poles 22 and 32, respectively, and contribute to the generation of torque of the rotor 11.

  When the three-phase drive current is supplied to the segment conductor (SC) winding 8 via the power supply circuit in the circuit housing box 5, the motor 1 configured as described above rotates the rotor 11 with the stator 6. Is generated, and the rotor 11 is rotationally driven.

Next, the operation of this embodiment will be described.
The first back magnet 41 is interposed in the radial gap between the back surface 22 c of the first claw-shaped magnetic pole 22 and the second core base 31. The second back magnet 42 is interposed in the radial gap between the back surface 32 c of the second claw-shaped magnetic pole 32 and the first core base 21. Thereby, the leakage magnetic flux from the gaps on the back surfaces 22c and 32c side of the claw-shaped magnetic poles 22 and 32 is suppressed by the back magnets 41 and 42, respectively.

  The first and second back magnets 41 and 42 are integrally formed with the first and second rotor cores 20 and 30, respectively. That is, the 1st rotor core 20 and the 1st back magnet 41, and the 2nd rotor core 30 and the 2nd back magnet 42 are comprised as integral parts, respectively. Thereby, compared with the structure by which each rotor core 20 and 30, the annular magnet 40, and each back magnet 41 and 42 were all made into a different body, the number of parts is suppressed. As a result, it is possible to reduce the assembly man-hours of the parts, and as a result, it is possible to contribute to the reduction of the assembling costs of the parts.

  Next, the manufacturing method of the rotor 11 of this embodiment is demonstrated. Below, the manufacturing method of the integrally molded product of the 1st rotor core 20 and the 1st back magnet 41 is mainly demonstrated according to Fig.6 (a)-(d). 6A to 6D show cross sections bent at a predetermined angle passing through the circumferential center of the two first claw-shaped magnetic poles 22.

FIG. 6A shows a first mold 51 for manufacturing an integrally molded product of the rotor core 20 and the back magnet 41.
First, as shown in FIG. 6B, the molded rotor core 20 is disposed in the first mold 51.

  Next, as shown in FIG. 6C, the second mold 52 is disposed above the first mold 51. Next, after a cavity formed between the second mold 52 and the back surface 22c of the claw-shaped magnetic pole 22 is filled with a mixed material of magnetic powder and resin material, the mixed material is solidified so that the bond magnet The back magnet 41 is formed. Thereby, the back magnet 41 is integrally formed with the rotor core 20 so as to be tightly fixed to the back surface 22c and the radially extending portion 22d of the claw-shaped magnetic pole 22.

  Next, the back magnet 41 is magnetized by a magnetizing device 53 that generates a magnetic field. As a result, the back magnet 41 is magnetized in the radial direction so that the radially outer side (the claw-shaped magnetic pole 22 side) is the north pole and the radially inner side is the south pole. Thereafter, a finished product of the integrally formed product of the rotor core 20 and the back magnet 41 shown in FIG. 6D is taken out from the first and second molds 51 and 52.

  An integrally molded product of the second rotor core 30 and the second back magnet 42 is also manufactured by the same procedure as described above. The magnetization direction of the second back magnet 42 is opposite to that of the first back magnet 41 (that is, the radially outer side is the S pole and the inner side is the N pole).

  Next, an integrally molded product composed of the first rotor core 20 and the first back magnet 41 and an integrally molded product composed of the second rotor core 30 and the second back magnet 42 sandwich the annular magnet 40, and The second claw-shaped magnetic poles 32 are assembled so as to be arranged between the circumferential directions of the first claw-shaped magnetic poles 22. Thereafter, the rotary shaft 12 is press-fitted and fixed in the insertion holes 21c, 31c of the core bases 21, 31, and the rotor 11 shown in FIGS. 3 and 4 is completed.

Next, characteristic effects of the present embodiment will be described.
(1) First and second back magnets 41 and 42 disposed in gaps formed on the back surfaces 22c and 32c of the first and second claw-shaped magnetic poles 22 and 32, respectively. 42 is integrally formed with the first and second rotor cores 20 and 30, respectively. That is, since the first rotor core 20 and the first back magnet 41, and the second rotor core 30 and the second back magnet 42 are each configured as an integral part, each rotor core 20, 30, the annular magnet 40 and each back magnet 41, Compared to a configuration in which all 42 are separated, the number of parts can be reduced. Moreover, it leads to suppressing the assembly man-hour of a part, and it can contribute to the reduction of the assembly cost of a part by extension. Further, the back magnets 41 and 42 can suppress the leakage magnetic flux from the gaps generated on the back surfaces 22 c and 32 c of the claw-shaped magnetic poles 22 and 32.

Note that the first embodiment of the present invention may be modified as follows.
In the first embodiment, an integrally molded product composed of the rotor cores 20 and 30 and the back magnets 41 and 42 is formed by insert molding using the rotor cores 20 and 30 as insert products. The back magnets 41 and 42 may be integrally formed by two-color molding.

  An example of a manufacturing method using two-color molding will be described with reference to FIGS. 7A to 7D also show cross sections bent at a predetermined angle passing through the center in the circumferential direction of the two first claw-shaped magnetic poles 22 as in FIGS. 6A to 6D.

FIG. 7A shows a first mold 61 for manufacturing an integrally molded product of the rotor core 20 and the back magnet 41 by two-color molding.
First, as shown in FIG. 7B, a cylindrical second mold 62 is disposed inside the first mold 61. Then, a hard magnetic powder constituting the back magnet 41 is filled into a cavity formed between the inner peripheral surface of the second mold 62 and the columnar central extension 61 a of the first mold 61.

  Next, the 2nd metal mold | die 62 is extracted and it fills with the soft magnetic powder which comprises the rotor core 20, as shown in FIG.7 (c). Thereafter, the third mold 63 is disposed above the first mold 61, and pressure is applied to the soft magnetic powder and the hard magnetic powder by the third mold 63 (pressure molding). Thereafter, by heating the soft magnetic powder and the hard magnetic powder, an integral part of the rotor core 20 and the back magnet 41 is formed. That is, the rotor core 20 is composed of a dust core.

  Next, the back magnet 41 is magnetized by a magnetizing device 53 that generates a magnetic field. As a result, the back magnet 41 is magnetized in the radial direction so that the radially outer side (the claw-shaped magnetic pole 22 side) is the north pole and the radially inner side is the south pole. Thereafter, the finished product of the integrally molded product of the rotor core 20 and the back magnet 41 shown in FIG. 7D is taken out from the first and third molds 61 and 63.

  An integrally molded product of the second rotor core 30 and the second back magnet 42 is manufactured in the same procedure. The magnetization direction of the second back magnet 42 is opposite to that of the first back magnet 41 (that is, the radially outer side is the S pole and the inner side is the N pole).

  According to this structure, since each rotor core 20 and 30 is comprised with a powder magnetic core, it becomes possible to compression-mold each rotor core 20 and 30 with each back magnet 41 and 42. FIG. Thereby, it can contribute to simplification of manufacture. Further, since the rotor cores 20 and 30 and the back magnets 41 and 42 are integrally formed by two-color molding, the integrity between the rotor cores 20 and 30 and the back magnets 41 and 42 can be improved.

  In the first embodiment, the back magnets 41 and 42 and the rotor cores 20 and 30 are integrally formed. However, the present invention is not particularly limited thereto. For example, the rotor cores 20 and 30 and the annular magnet 40 are used. And may be integrally formed. In this case, the back magnets 41 and 42 may be fixed to the first claw-shaped magnetic poles 22 by bonding or the like. Also, the back magnets 41 and 42 are omitted, and the rotor 11 is annularly connected to the rotor cores 20 and 30. You may comprise from the magnet 40. FIG. Further, the rotor cores 20 and 30 and the annular magnet 40 may be integrally formed, or the annular magnet 40 may be integrally formed with one of the first and second rotor cores 20 and 30.

  According to such a configuration, at least one of the first and second rotor cores 20 and 30 and the annular magnet 40 are formed as an integral component, so that the component of the rotor 11 is a component compared to a configuration in which all components are separated. The score can be reduced. Moreover, it leads to suppressing the assembly man-hour of a part, and it can contribute to the reduction of the assembly cost of a part by extension.

(Second Embodiment)
The rotor 11A of the present embodiment shown in FIG. 8 has a configuration in which the rotor cores 20 and 30, the annular magnet 40, and the back magnets 41 and 42 are all integrally formed. In addition, about the structure similar to the said 1st Embodiment, the same code | symbol is attached | subjected and the detailed description is abbreviate | omitted.

  As shown in FIGS. 8 and 9D, in the rotor 11 </ b> A of the present embodiment, the radially inner side surface 41 b of each first back magnet 41 is the outer peripheral surface of the annular magnet 40 and the outer peripheral surface of the second core base 31. It is spaced radially from 31d. Similarly, the radially inner side surface 42 b of each second back magnet 42 is spaced radially from the outer circumferential surface of the annular magnet 40 and the outer circumferential surface 21 d of the first core base 21. The outer peripheral surfaces 21d and 31d of the core bases 21 and 31 and the outer peripheral surface of the annular magnet 40 have the same diameter.

Next, a method for manufacturing the rotor 11A of the present embodiment will be described.
FIG. 9A shows a first mold 71 for manufacturing an integrally molded product composed of the rotor cores 20 and 30, the annular magnet 40 and the back magnets 41 and 42 by two-color molding.

  First, as shown in FIG. 9B, in the first mold 71, the soft magnetic powder constituting the rotor cores 20 and 30, the hard magnetic powder constituting the annular magnet 40 and the back magnets 41 and 42, respectively. The body and the disappeared powder P made of a sublimate such as naphthalene are filled in a predetermined manner.

  Next, a second mold 72 (see FIG. 3) is disposed above the first mold 71, and pressure is applied to the powder filled in the first mold 71 by the second mold 72 (applying pressure). Pressure forming). Thereafter, by heating the soft magnetic powder, the hard magnetic powder, and the disappearing powder P, the rotor cores 20 and 30, the annular magnet 40, and the back magnets 41 and 42 are formed as shown in FIG. An integral part is formed. That is, each rotor core 20 and 30 is comprised with a dust core. In addition, the powder P (naphthalene) is sublimated by this heating, whereby the radial inner surface 41b of the first back magnet 41, the annular magnet 40 and the second core base 31, and the second back magnet. A radial gap is formed between the radially inner side surface 42 b of the ring 42 and the annular magnet 40 and the first core base 21.

  Next, the back magnets 41 and 42 and the annular magnet 40 are magnetized by a magnetizing device 53 that generates a magnetic field. The magnetic flux from the magnetizing device 53 disposed on the radially outer side of the first claw-shaped magnetic pole 22 passes through the first claw-shaped magnetic pole 22 and the first back magnet 41 in the radial direction, and from there in the first core base 21. Passing radially inward, it passes through the annular magnet 40 in the axial direction. Similarly, the magnetic flux from the magnetizing device 53 disposed on the radially outer side of the second claw-shaped magnetic pole 32 passes through the second claw-shaped magnetic pole 32 and the second back magnet 42 in the radial direction, and from there the second core It passes through the base 31 inward in the radial direction and passes through the annular magnet 40 in the axial direction. As a result, the first back magnet 41 and the second back magnet 42 are magnetized so as to have different polarities, and the annular magnet 40 is magnetized in the axial direction.

  Thereafter, the integrally molded product shown in FIG. 9D is taken out from the first and second molds 71 and 72, and the rotary shaft 12 is press-fitted and fixed in the insertion holes 21c and 31c of the core bases 21 and 31, respectively. The rotor 11A shown in FIG.

  Also according to this embodiment, the same effect as the effect (1) of the first embodiment can be obtained. In addition, since each of the back magnets 41 and 42 is integrally formed with each of the rotor cores 20 and 30 and the annular magnet 40, they can be configured as an integral part, and as a result, the number of parts can be reduced. Moreover, in this embodiment, since each rotor core 20 and 30 is comprised with a powder magnetic core, it becomes possible to compression-mold each rotor core 20 and 30 with the annular magnet 40 and each back magnet 41 and 42. FIG. Thereby, it can contribute to simplification of manufacture. Moreover, since each rotor core 20 and 30, the annular magnet 40, and each back magnet 41 and 42 are integrally molded by two-color molding, the integrity of the rotor 11A can be improved.

In addition, you may change each embodiment of this invention as follows.
In the second embodiment, a sublimate (for example, naphthalene) is used for the lost powder P. However, for example, a melt or a water solution (for example, sodium chloride) may be used for the lost powder P.

  In each of the above embodiments, first and second interpole magnets 43 and 44 as shown in FIG. 10 may be provided as auxiliary magnets. FIG. 10 shows an example in which the interpolar magnets 43 and 44 are provided in the rotor 11 of the first embodiment.

  The first and second interpole magnets 43 and 44 are arranged between the first claw-shaped magnetic pole 22 and the second claw-shaped magnetic pole 32 in the circumferential direction. More specifically, the first interpole magnet 43 includes a flat surface formed by one circumferential end surface 22 a of the first claw-shaped magnetic pole 22 and a circumferential end surface of the first back magnet 41, and the second claw-shaped magnetic pole 32. Is located between the other circumferential end surface 32b and a flat surface formed by the circumferential end surface of the second back magnet 42. The second interpole magnet 44 has the same shape as the first interpole magnet 43, and is formed by the other circumferential end face 22 b of the first claw-shaped magnetic pole 22 and the circumferential end face of the first back magnet 41. And the flat surface formed by one circumferential end surface 32a of the second claw-shaped magnetic pole 32 and the circumferential end surface of the second back magnet 42. The first and second interpole magnets 43 and 44 have the same polarity as each of the first and second claw-shaped magnetic poles 22 and 32 (the first claw-shaped magnetic pole 22 side is N-pole and the second claw-shaped It is magnetized in the circumferential direction (so that the magnetic pole 32 side becomes the S pole).

  In such a configuration, the first and second interpole magnets 43 and 44 are formed integrally with the first and second rotor cores 20 and 30, respectively, or both the first and second interpole magnets 43 and 44 are formed in the first and second poles. By integrally molding either one of the second rotor cores 20 and 30, the number of components can be reduced as compared with a configuration in which all the components of the rotor 11 are separated. Moreover, it leads to suppressing the assembly man-hour of a part, and it can contribute to the reduction of the assembly cost of a part by extension. Note that the back magnets 41 and 42 and the rotor cores 20 and 30 may not be integrally formed as in the first embodiment, but only the interpolar magnets 43 and 44 may be integrally formed with the rotor cores 20 and 30. Alternatively, the back magnets 41 and 42 may be omitted, and the interpolar magnets 43 and 44 may be integrally formed with the rotor cores 20 and 30.

  Further, in the configuration in which the interpolar magnets 43 and 44 are provided in the rotor 11A of the second embodiment, all the components of the rotor 11A excluding the rotating shaft 12 (that is, the rotor cores 20 and 30, the annular magnet 40, and the back magnets 41). , 42 and the interpolar magnets 43, 44) are integrally formed, the number of components of the rotor 11A excluding the rotating shaft 12 can be reduced to one, which is more effective.

-The number of poles (number of claw-shaped magnetic poles 22 and 32) of the stator 6 and the rotor 11 of each of the above embodiments may be changed as appropriate according to the configuration.
-In each above-mentioned embodiment, you may change suitably the shape of the 1st and 2nd rotor cores 20 and 30 according to composition.

  In each of the above embodiments, the annular magnet 40 is magnetized so that the first claw-shaped magnetic pole 22 functions as the N pole and the second claw-shaped magnetic pole 32 functions as the S pole. Conversely, the first claw-shaped magnetic pole 22 may function as the S pole and the second claw-shaped magnetic pole 32 may function as the N pole.

  In each of the above embodiments, one annular magnet 40 is used as a field magnet. However, a plurality of permanent magnets are arranged between the first and second core bases 21 and 31 around the rotary shaft 12. You may employ | adopt the structure to do.

In each of the above embodiments, no particular reference is made to the winding method of the stator 6 on the teeth, but concentrated winding or distributed winding may be used.
Next, technical ideas that can be grasped from the above embodiments and other examples will be described below.

(A) a first rotor core having a plurality of first claw-shaped magnetic poles projecting radially outward and extending in the axial direction on the outer periphery of a substantially disc-shaped first core base;
A plurality of second claw-shaped magnetic poles project radially outward and extend in the axial direction on the outer periphery of the substantially disk-shaped second core base, and correspond to each of the second claw-shaped magnetic poles. A second rotor core disposed between the first claw-shaped magnetic poles of the first rotor core;
Arranged between the first core base and the second core base in the axial direction and magnetized in the axial direction, the first claw-shaped magnetic pole functions as the first magnetic pole, and the second claw-shaped A field magnet that causes the magnetic pole to function as a second magnetic pole;
A method of manufacturing a rotor comprising a gap formed on the back surface of each claw-shaped magnetic pole and an auxiliary magnet disposed in at least one of the gap between the first claw-shaped magnetic pole and the second claw-shaped magnetic pole in the circumferential direction. And
A method for manufacturing a rotor, wherein the auxiliary magnet is formed integrally with at least one of the first and second rotor cores.

  Thereby, the auxiliary magnet disposed in at least one of the gap formed on the back surface of each claw-shaped magnetic pole and the gap between the claw-shaped magnetic poles in the circumferential direction is an integral part with at least one of the first and second rotor cores. . Thereby, compared with the structure by which each rotor core, the field magnet, and the auxiliary magnet were made into the different bodies, the number of parts can be suppressed. Moreover, it leads to suppressing the assembly man-hour of a part, and it can contribute to the reduction of the assembly cost of a part by extension. Furthermore, it can be set as the structure which magnetic flux does not leak easily from the clearance gap between rotors with an auxiliary magnet.

(B) a first rotor core having a plurality of first claw-shaped magnetic poles projecting radially outward and extending in the axial direction on the outer periphery of a substantially disc-shaped first core base;
A plurality of second claw-shaped magnetic poles project radially outward and extend in the axial direction on the outer periphery of the substantially disk-shaped second core base, and correspond to each of the second claw-shaped magnetic poles. A second rotor core disposed between the first claw-shaped magnetic poles of the first rotor core;
Arranged between the first core base and the second core base in the axial direction and magnetized in the axial direction, the first claw-shaped magnetic pole functions as the first magnetic pole, and the second claw-shaped A method of manufacturing a rotor including a field magnet that causes a magnetic pole to function as a second magnetic pole,
A method for manufacturing a rotor, wherein the field magnet is formed integrally with at least one of the first and second rotor cores.

  Thereby, since at least one of the first and second rotor cores and the field magnet are integrated, the number of parts can be reduced as compared with a configuration in which each rotor core and field magnet are all separated. Moreover, it leads to suppressing the assembly man-hour of a part, and it can contribute to the reduction of the assembly cost of a part by extension.

  DESCRIPTION OF SYMBOLS 1 ... Motor, 11 and 11A ... Rotor, 12 ... Rotary shaft, 20 ... 1st rotor core, 21 ... 1st core base, 22 ... 1st claw-shaped magnetic pole, 22c, 32c ... Back surface, 30 ... 2nd rotor core, 31 ... Second core base, 32 ... second claw-shaped magnetic pole, 40 ... annular magnet (field magnet), 41 ... first back magnet (auxiliary magnet), 42 ... second back magnet (auxiliary magnet), 43 ... first pole Inter-magnet (auxiliary magnet), 44 ... second inter-pole magnet (auxiliary magnet).

Claims (6)

A first rotor core having a plurality of first claw-shaped magnetic poles protruding radially outward and extending in the axial direction at an outer peripheral portion of a substantially disc-shaped first core base;
A plurality of second claw-shaped magnetic poles project radially outward and extend in the axial direction on the outer periphery of the substantially disk-shaped second core base, and correspond to each of the second claw-shaped magnetic poles. A second rotor core disposed between the first claw-shaped magnetic poles of the first rotor core;
Arranged between the first core base and the second core base in the axial direction and magnetized in the axial direction, the first claw-shaped magnetic pole functions as the first magnetic pole, and the second claw-shaped A field magnet that causes the magnetic pole to function as a second magnetic pole;
An auxiliary magnet disposed in at least one of a gap formed on the back surface of each claw-shaped magnetic pole and a gap between the first claw-shaped magnetic pole and the second claw-shaped magnetic pole in the circumferential direction;
The auxiliary magnet is integrally formed with at least one of the first and second rotor cores. The rotor according to claim 1, wherein
The auxiliary magnet has a first back magnet arranged in a gap generated on the back surface of the first claw-shaped magnetic pole, and a second back magnet arranged in a gap generated on the back surface of the second claw-shaped magnetic pole,
The first back magnet is integrally formed with the first rotor core,
The rotor, wherein the second back magnet is integrally formed with the second rotor core. The rotor according to claim 1 or 2,
The auxiliary magnet is integrally formed with each rotor core and the field magnet. A first rotor core having a plurality of first claw-shaped magnetic poles protruding radially outward and extending in the axial direction at an outer peripheral portion of a substantially disc-shaped first core base;
A plurality of second claw-shaped magnetic poles project radially outward and extend in the axial direction on the outer periphery of the substantially disk-shaped second core base, and correspond to each of the second claw-shaped magnetic poles. A second rotor core disposed between the first claw-shaped magnetic poles of the first rotor core;
Arranged between the first core base and the second core base in the axial direction and magnetized in the axial direction, the first claw-shaped magnetic pole functions as the first magnetic pole, and the second claw-shaped A field magnet that causes the magnetic pole to function as a second magnetic pole,
The rotor, wherein the field magnet is formed integrally with at least one of the first and second rotor cores. The rotor according to any one of claims 1 to 4,
Each of the rotor cores is composed of a dust core.   The motor provided with the rotor of any one of Claims 1-5.