Toyota Jidosha Kabushiki Kaisha

Kenta Takeshima

Takashi Yamamoto

Shuzaburo Kita

Shintaro Nakano

Ayumu Yageta

A rotor for an electric motor may include a rotor core having a hole; a magnet inserted in the hole; and a sheet disposed between an inner surface of the hole and a side surface of the magnet, wherein the side surface faces the inner surface. The sheet may include a first contact layer contacting the inner surface of the hole; a second contact layer contacting the side surface of the magnet; and a body layer including a porous structure and disposed between the first contact layer and the second contact layer. The body layer may have a higher porosity than at least one of the first contact layer and the second contact layer.

Rotor for electric motor, manufacturing method thereof, and manufacturing method of sheet used in the manufacturing method

A method of manufacturing magnets and a method of manufacturing a rotor are provided. An intermediate member includes a sheet and magnet bodies. The sheet includes a first sheet surface and a second sheet surface on a side opposite to the first sheet surface. The magnet bodies are located on the first sheet surface. A first die is made of an elastic material having an elastic coefficient lower than the elastic coefficient of the magnet bodies. The intermediate member is arranged between the first die and a second die such that the second sheet surface of the sheet faces the first die. The first die and the second die hold the intermediate member in between. Accordingly, the sheet is cut at positions between adjacent ones of the magnet bodies.

Method of manufacturing magnets and method of manufacturing rotor

A method of assembling a rotor including a cylindrical rotor core and a permanent magnet that is held in a hole portion provided in the rotor core such that a longitudinal direction of the permanent magnet is parallel to an axis of the rotor core. The method includes: a load measuring step of measuring a load applied to the permanent magnet or/and the rotor core when the permanent magnet is brought into contact with the rotor core; and a moving step of moving the permanent magnet or/and the rotor core so as to change a position of the permanent magnet relative to the rotor core, depending on data relating to the load measured at the load measuring step, such that a positional deviation between the permanent magnet and the hole portion is reduced. Also disclosed is a control device for a rotor assembly apparatus.

Rotor assembling method

A sheet-shaped insulating member including a thermoplastic resin fiber and an inorganic fiber is arranged on a surface of a magnet body. The insulating member is compressed while being heated to a temperature higher than or equal to a glass transition temperature of the thermoplastic resin fiber, so that the insulating member is thermocompression-bonded to the magnet body in a state in which the inorganic fiber is elastically compressed. A magnet is thus formed. With the magnet arranged in a slot of a rotor core, the magnet is heated to a temperature higher than or equal to the glass transition temperature of the thermoplastic resin fiber. This causes the inorganic fiber to restore elasticity, so that the magnet is fixed to the rotor core.

Method of manufacturing magnet and method of manufacturing rotor

A manufacturing method of a rotor may be provided with: arranging a magnet and a thermoplastic in a magnet fixing portion of a rotor core including a laminate in which a plurality of metal plates is laminated, the magnet fixing portion including a hole and/or a trench provided in the rotor core and extending along a lamination direction of the laminate; heating the rotor core while rotating the rotor core around a center axis of the rotor core, with the center axis intersecting a vertical direction; and cooling the rotor core to fix the magnet to the rotor core via the thermoplastic while rotating the rotor core around the center axis, with the center axis intersecting the vertical direction.

Method of manufacturing rotor

A method of manufacturing a rotor for a rotating electric machine. The rotor includes a rotor core and at least one magnet fixed in at least one magnet fixing portion provided in the rotor core. The method includes: (a) placing the at least one magnet and at least one fixing member in the at least one magnet fixing portion such that each of the at least one fixing member is positioned between a corresponding one of the at least one magnet fixing portion and a corresponding one of the at least one magnet; and (b) applying an electric current to the at least one magnet to heat the at least one fixing member by heat generated by an electrical resistance of the at least one magnet, and fixing the at least one magnet to the at least one magnet fixing portion through the heated at least one fixing member.

Method for manufacturing rotor for rotor electric machine

A manufacturing method of a rotor for an electric motor is disclosed herein. The rotor may include a rotor core having a through hole that extends along an axial direction of the rotor; a magnet inserted in the through hole; and a sheet disposed between an inner surface of the through hole and the magnet. The method may include inserting the sheet into the through hole such that the sheet extends through the through hole; and inserting the magnet into the through hole while the sheet is pulled at axial ends of the sheet in opposite directions to apply tension to the sheet and press the sheet against the inner surface.

Manufacturing method of rotor for electric motor

A method of manufacturing a rotor is disclosed. A magnet is inserted into a magnet hole of a rotor core. The method comprises inserting an insertion member into the magnet hole having a first opening and a second opening. The method comprises fixing the magnet to the insertion member extending out from the second opening. The method comprises inserting the magnet, which is fixed to the insertion member, into the magnet hole from the second opening by pulling the insertion member extending out from the first opening in a direction separating away from the rotor core. The method comprises cutting the insertion member extending out from the first opening.

Growing community of inventors

Okazaki, Japan

Kenta Takeshima