The method for manufacturing a disk of a clutch rotor of an electromagnetic clutch is characterized by including the following steps: forming a square plate by cutting a longitudinal plate, the side length of the square plate being the same as the width of the longitudinal plate, and The square plate is punched by a cylindrical recess in a mold, and the diameter of the cylindrical recess is the same as the diagonal length of the square plate. The square plate may not be a square.
Figure 1 shows the structure of a common electromagnetic clutch. This clutch is mounted on a compressor and is used to control the transmission of driving power from a drive source to the compressor. The electromagnetic clutch contains a U-shaped clutch rotor. The rotor has a ring portion. And is rotatably mounted on the outer surface of the annular bush through a radial bearing, and the bush extends axially from the front plate of the compressor. The pulley is fixed to the outer surface of the annular portion to receive the transmission belt. The electromagnet is fixedly disposed in the hollow portion and defines a narrow gap with the annular portion of the electromagnetic clutch rotor and the annular portion. A hub with a radially extending flange portion is fixed to the end of the compressor drive shaft by means of bolts. The brake plate together with a plurality of leaf springs is fixed on one end surface of the flange portion of the hub with rivets on one end thereof. The armature plate is arranged radially outward of the flange portion and is fixed to the other end of the leaf spring by a rivet.
The clutch rotor always rotates through a transmission belt and receives a rotational force from a driving source. If the electromagnet is excited at this time, a magnetic flux flows between the clutch rotor and the electromagnet, so that the armature plate absorbs one end of the clutch rotor. Therefore, the armature plate rotates with the clutch rotor, thereby attracting the armature plate to one end of the clutch rotor. Therefore, the armature plate rotates with the clutch rotor, thereby transmitting the rotational force from the armature plate to the clutch rotor to drive the drive shaft of the compressor.
Referring to FIG. 2, there is shown a method of processing a disc, which can be used to manufacture a clutch rotor of the above-mentioned electromagnetic clutch. The discs are made by punching the sheets one by one with a punch. At this time, the longitudinal sheets must be punched at a certain interval. For example, the spacing between the discs is two to three times the width of the longitudinal sheet. The disc is then processed with a punch to make a clutch rotor. Therefore, since the disc is made according to the method described above, all the parts indicated by diagonal lines of the longitudinal plate become waste, thereby increasing the production cost.
This section provides a method for processing discs that can be used to make electromagnetically-coupled rotors, reducing waste during rotor production. In addition, the disc can be used to manufacture the clutch rotor of an electromagnetic clutch, and the production cost of the rotor can be reduced.
Referring to the drawings, FIG. 1 is a sectional view of a conventional electromagnetic clutch.
FIG. 2 is a schematic diagram illustrating a conventional method of processing a disk that can be used to manufacture a clutch rotor of an electromagnetic clutch.
FIG. 3 is a schematic diagram illustrating a method of processing a disc that can be used to manufacture a clutch rotor of the electromagnetic clutch.
FIG. 4 is a schematic diagram illustrating a conventional method of manufacturing a clutch rotor of an electromagnetic clutch.
Fig. 5 is a sectional view of a clutch rotor made by the above method.
According to the first step of manufacturing the disc, the longitudinal plate is cut into squares, and one side of the square is the width of the longitudinal plate. That is, the longitudinal plate is cut along the dotted line shown in FIG. 3. As described below, the diagonal of the square plate shown by the two-dot chain line is the diameter of the manufactured disc. The shape of the disc is indicated by a dotted line.
In a second step, a square plate is placed in a cylindrical recess of the mold, the diameter of the recess being the same as the diagonal length of the square plate. Then, in the ordinary stamping process, the convex part on the lower end face of the punch is punched into a square plate. As shown in FIG. 3, since the square plate is punched in a cylindrical recess, the square plate is deformed into a disc shape. At the same time, a concave portion is formed on one side of the ring at a position corresponding to the convex portion of the punch.
In the case of manufacturing the clutch rotor, since the above-mentioned disc is used, a hole is formed first through the bottom surface of the concave portion. As shown in FIG. 4, a disc is placed in a concave portion of a mold, and a convex portion is fitted at the center of the mold, and the diameter of the convex portion is the same as the diameter of the hole. After that, the punch is punched with a punch having a protruding portion, and a ring placed concentrically with the protruding portion of the mold is formed into the shape of an electromagnetic clutch rotor.
Since the clutch rotor shown in FIG. 5 is formed as described above, although one embodiment of manufacturing a disc using a square plate is described above, it is not necessary to use a square plate, and processing errors can be absorbed during deformation processing.