JP-2026075222-A - Method for manufacturing a rotor and method for manufacturing a rotating electric machine

JP2026075222AJP 2026075222 AJP2026075222 AJP 2026075222AJP-2026075222-A

Abstract

[Problem] To provide a method for manufacturing a rotor equipped with permanent magnets in a Halbach arrangement that is easy to assemble. [Solution] The process includes steps S1 of arranging a non-magnetic mold that forms a space corresponding to the shapes of the rotor main magnet and rotor sub-magnet between itself and a magnetic mold; step S2 of injecting magnet material; step S3 of controlling the orientation magnetic flux of the magnet material using an orientation magnetic flux control magnet; step S4 of magnetizing the magnet material to form the rotor main magnet and rotor sub-magnet; step S5 of releasing the rotor main magnet and rotor sub-magnet from the mold; and step S6 of assembling the rotor main magnet and rotor sub-magnet into the rotor back yoke and rotor magnetic body, wherein the orientation magnetic flux control magnet controls the orientation magnetic flux of the rotor main magnet in a direction parallel to the radial direction and controls the orientation magnetic flux of the rotor sub-magnet in a direction parallel to the circumferential direction. [Selection Diagram] Figure 4

Inventors

鈴木寛典
乙坂純香

Assignees

三菱電機株式会社

Dates

Publication Date: 20260508
Application Date: 20241022

Claims (9)

A method for manufacturing a rotor comprising: an annular rotor back yoke made of a magnetic material; a plurality of rotor main magnets arranged circumferentially spaced apart on the surface of the rotor back yoke; a plurality of rotor magnetic materials arranged circumferentially spaced apart on the opposite side of the plurality of rotor main magnets from the side facing the rotor back yoke; and a plurality of rotor auxiliary magnets arranged between the plurality of rotor magnetic materials, wherein A step of arranging a magnetic mold composed of a first magnetic mold and a second magnetic mold having the same cross-sectional shape as the rotor magnetic material and the rotor back yoke, respectively, and a non-magnetic mold that forms a space between the magnetic mold and the rotor main magnet and the rotor sub-magnet corresponding to the shapes of the rotor main magnet and the rotor sub-magnet, A step of injecting a magnetic material into the space formed between the magnetic mold and the non-magnetic mold, A step of controlling the orientation magnetic flux of the magnet raw material injected into the space formed between the magnetic mold and the non-magnetic mold using a magnet for controlling the orientation magnetic flux, A step of releasing the rotor main magnet and the rotor sub-magnet from the magnetic mold and the non-magnetic mold, The process includes a step of incorporating the molded rotor main magnet and rotor sub-magnet into the rotor back yoke and rotor magnetic material, The orientation flux control magnet controls the orientation flux of the rotor main magnet in a direction parallel to the radial direction and controls the orientation flux of the rotor sub-magnet in a direction parallel to the circumferential direction. A method for manufacturing a rotor, characterized in that the rotor main magnet and the rotor sub-magnet are magnetized after the orientation magnetic flux is controlled by the orientation magnetic flux control magnet.
The method for manufacturing a rotor according to claim 1, characterized in that at least one of the following is applied: using the rotor magnetic material as the first magnetic mold, and using the rotor back yoke as the second magnetic mold.
The method for manufacturing a rotor according to claim 1 or 2, characterized in that the rotor main magnet and the rotor sub-magnet are connected by a magnetic bridge.
The method for manufacturing a rotor according to claim 1 or 2, characterized in that the rotor magnetic material and the rotor auxiliary magnet have a mating portion with respect to each other.
The rotor manufacturing method according to claim 1 or 2, characterized in that the rotor back yoke has positioning protrusions that restrict the position of the rotor main magnet.
The method for manufacturing a rotor according to claim 1 or 2, characterized in that the rotor back yoke and the rotor magnetic material are fastened together by a magnetic bridge.
The method for manufacturing a rotor according to claim 1 or 2, characterized in that multiple rotor magnetic materials, spaced apart in the circumferential direction, are fastened together by magnetic bridges.
A method for manufacturing a rotating electric machine, characterized by coaxially arranging a stator having a stator core and stator coils, and a rotor manufactured by the rotor manufacturing method described in claim 1 or 2, with a gap between them.
The method for manufacturing a rotating electric machine according to claim 8, characterized in that the width of the gap between the rotor's auxiliary magnet and the stator is greater than the width of the gap between the rotor's magnetic material and the stator.

Description

This disclosure relates to a method for manufacturing a rotor and a method for manufacturing a rotating electric machine. In rotating electric machines equipped with permanent magnets, rotors with a Halbach arrangement of permanent magnets have been proposed for the purpose of concentrating the magnetic flux. As a rotor equipped with Halbach arrangement permanent magnets, a rotor is disclosed in which multiple main pole permanent magnets magnetized in the direction of the generated magnetic field, and secondary pole permanent magnets positioned between the main pole permanent magnets, are fixed to a magnetic material (see, for example, Patent Document 1). Patent No. 6947340 This is a cross-sectional view of a rotating electric machine according to Embodiment 1.This is a cross-sectional view of the rotor according to Embodiment 1.This is a cross-sectional view of the rotor according to Embodiment 1.This is a flowchart showing the method for manufacturing a rotor according to Embodiment 1.This is a diagram illustrating the manufacturing method of a rotor according to Embodiment 1.This is a diagram illustrating the manufacturing method of a rotor according to Embodiment 1.This is a diagram illustrating the manufacturing method of a rotor according to Embodiment 1.This is a diagram illustrating the manufacturing method of a rotor according to Embodiment 1.This is a diagram illustrating the manufacturing method of a rotor according to Embodiment 1.This is a diagram illustrating the manufacturing method of a rotor according to Embodiment 2.This is a diagram illustrating the manufacturing method of a rotor according to Embodiment 2.This is a diagram illustrating the manufacturing method of a rotor according to Embodiment 2.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 3.This is a cross-sectional view of the rotor according to Embodiment 4.This is a cross-sectional view of the rotor according to Embodiment 4.This is a cross-sectional view of the rotor according to Embodiment 4.This is a cross-sectional view of the rotor according to Embodiment 4.This is a cross-sectional view of the rotor according to Embodiment 4.This is a cross-sectional view of the rotor according to Embodiment 4.This is a cross-sectional view of the rotor according to Embodiment 4.This is a cross-sectional view of the rotor according to Embodiment 5.This is a cross-sectional view of the rotor according to Embodiment 5.This is a cross-sectional view of the rotor according to Embodiment 5.This is a cross-sectional view of the rotor according to Embodiment 5.This is a cross-sectional view of the rotor according to Embodiment 5. Hereinafter, a rotor and a rotating electric machine relating to embodiments for implementing this disclosure will be described in detail with reference to the drawings. In each drawing, the same reference numerals indicate the same or corresponding parts. The structure of the rotating electric machine described in this disclosure is one in which the rotor is assembled sequentially on the inner diameter side and the stator on the outer diameter side. Alternatively, the rotating electric machine may have a structure in which the stator is assembled sequentially on the inner diameter side and the rotor on the outer diameter side. Furthermore, this disclosure is applicable not only to rotating electric machines but also to rotating machinery such as magnetic reducers. In addition, while this disclosure describes a cylindrical rotating electric machine, the contents of this disclosure are also applicable to disc rotating, flat plate linear, and cylindrical linear types. Embodiment 1. Figure 1 is a cross-sectional view of a rotating electric machine according to Embodiment 1. Figure 1 is a cross-sectional view of a plane perpendicular to the rotational axis and shows one-quarter of a cylindrical rotating electric machine. Figure 1 shows the basic structure of a rotating electric machine equipped with Halbach array permanent magnets according to this embodiment. In this embodiment, the rotating electric machine 1 has a rotor 10 positioned on the inner diameter side and a stator 20 positioned on the outer diameter side. The rotor 10 and stator 20 are coaxially arranged with a gap between them, and the rotor 10 rotates relative to the stator 20 around its rotational axis. The rotor 10, from the inner diameter side outwards, consists of a rotor shaft 11 (which s