CN108028588B - Motor and air conditioner - Google Patents
Motor and air conditioner Download PDFInfo
- Publication number
- CN108028588B CN108028588B CN201580082985.XA CN201580082985A CN108028588B CN 108028588 B CN108028588 B CN 108028588B CN 201580082985 A CN201580082985 A CN 201580082985A CN 108028588 B CN108028588 B CN 108028588B
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- rotor
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- stator
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
- H02K29/06—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices
- H02K29/08—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices using magnetic effect devices, e.g. Hall-plates, magneto-resistors
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Brushless Motors (AREA)
Abstract
The motor (100) is provided with a stator (42), a rotor magnet, a sensor magnet (11), a substrate (46), and a magnetic sensor (47), wherein the circumferential position of a 1 st magnetic pole intermediate portion between adjacent 1 st and 2 nd magnetic poles magnetized by the rotor magnet is a 1 st position, the circumferential position of a 2 nd magnetic pole intermediate portion between adjacent 3 rd and 4 th magnetic poles magnetized by the sensor magnet (11) is a 2 nd position, and a phase difference correcting the deviation of the installation position of the magnetic sensor (47) is added between the 1 st and 2 nd positions to magnetize the rotor magnet and the sensor magnet (11).
Description
Technical Field
The present invention relates to a motor and an air conditioner including the motor.
Background
The motor of patent document 1 includes: a cylindrical stator; a rotor shaft coaxial with the stator; a rotor disposed inside the stator and fixed to the rotor shaft; a main magnet formed on the rotor; and a sensor magnet attached to the rotor shaft. The sensor magnet has a magnetic pole corresponding to a magnetic pole of the main magnet, and the stator of the motor has a magnetic sensor disposed close to the sensor magnet.
In the motor of patent document 1, the sensor magnet is attached so that the magnetic pole of the sensor magnet is at a phase angle offset relative to the magnetic pole of the main magnet.
Documents of the prior art
Patent document
Patent document 1: japanese laid-open patent publication No. 10-201208
Disclosure of Invention
Technical problem to be solved by the invention
In the motor of patent document 1, the energization of the coils of the stator core is controlled in accordance with the position of the rotor, so that the motor can be driven with high efficiency and low noise. However, the detection of the position of the rotor is affected by the magnetization positions of the magnetic poles of the main magnet and the sensor magnet, and the installation position of the magnetic sensor to the stator. That is, an error occurs in the detected position of the rotor due to the variation in the magnetized position of the rotor and the variation in the installation position of the magnetic sensor to the stator, which is a problem in achieving high efficiency of the motor. In particular, it is difficult to improve the accuracy itself of the position of the magnetic sensor to the stator. Therefore, the conventional motor disclosed in patent document 1 has the following problems: when a rotor is assembled to a stator in which the magnetic sensor is disposed at a different position, the rotor is detected at a different position, and as a result, it is difficult to improve the operating efficiency of the motor.
The present invention has been made in view of the above problems, and an object of the present invention is to obtain a motor which improves the operation efficiency.
Technical scheme for solving technical problem
In order to solve the above problems and achieve the object, a motor according to the present invention includes: an annular stator; and a ring-shaped rotor magnet disposed coaxially with the stator on the inner side of the stator, and having a plurality of magnetic poles in which a 1 st magnetic pole and a 2 nd magnetic pole different from the 1 st magnetic pole are alternately arranged in the circumferential direction of the stator. The motor of the present invention includes a ring-shaped sensor magnet disposed coaxially with the rotor magnet and facing the rotor magnet, and having a plurality of magnetic poles in which a 3 rd magnetic pole having the same polarity as the 1 st magnetic pole and a 4 th magnetic pole having the same polarity as the 2 nd magnetic pole are alternately arranged in the circumferential direction of the stator. Further, the motor of the present invention includes: and a magnetic sensor disposed opposite to the sensor magnet and detecting a rotational position of the sensor magnet. In the motor of the present invention, the 1 st position is the 1 st position between the 1 st magnetic pole and the 2 nd magnetic pole adjacent to each other. In the motor of the present invention, the position between the 2 nd magnetic poles of the adjacent 3 rd magnetic pole and the 4 th magnetic pole is the 2 nd position. In the motor of the present invention, the rotor magnet and the sensor magnet are magnetized by adding a phase difference that reduces a variation in the installation position of the magnetic sensor between the 1 st position and the 2 nd position.
Effects of the invention
According to the present invention, the effect of improving the work efficiency can be achieved.
Drawings
Fig. 1 is a diagram showing a structure of a motor according to embodiment 1 of the present invention.
Fig. 2 is a perspective view of a stator mounting portion in which substrates are assembled in embodiment 1 of the present invention.
Fig. 3 is a perspective view of the stator mounting portion shown in fig. 2 as viewed from the load side.
Fig. 4 is a side view of the substrate shown in fig. 2 viewed from the opposite side to the load.
Fig. 5 is a side view of the substrate shown in fig. 2 as viewed from the load side.
Fig. 6 is a side view of the rotor with the bearing assembled shown in fig. 1, as viewed from the load side.
Fig. 7 is a sectional view VII-VII shown in fig. 6.
Fig. 8 is a side view of the rotor with the bearing assembled shown in fig. 1, as viewed from the opposite side to the load.
Fig. 9 is a side view of the rotor shown in fig. 1 as viewed from the load side.
Fig. 10 is an X-X sectional view shown in fig. 9.
Fig. 11 is a side view of the rotor shown in fig. 1 as viewed from the opposite side to the load.
Fig. 12 is a side view of the rotor magnet as viewed from the load side.
Fig. 13 is a cross-sectional view of XIII-XIII shown in fig. 12.
Fig. 14 is a side view of the rotor magnet shown in fig. 13 viewed from the opposite side to the load.
Fig. 15 is a diagram showing magnetization distribution of the rotor according to embodiment 1 of the present invention.
Fig. 16 is a diagram showing an induced voltage induced by a coil wound around a stator and an output waveform of a magnetic sensor in embodiment 1 of the present invention.
Fig. 17 is a diagram showing an example of the structure of an air conditioner according to embodiment 2 of the present invention.
Reference numerals
1: a rotor shaft; 2: knurling (knurling); 3: a back yoke; 4: a bearing abutment; 5. 52: a protrusion; 6: a gate opening; 7: a base; 8. 12: a cylindrical portion; 9: a plastic magnet; 10: a rotor magnet; 10 a: 1 st end face; 10 b: a 2 nd end surface; 11: a sensor magnet; 13. 48: a shaft hole; 14: a detected part; 15. 53: an aperture; 16. 16a, 16 b: a recess; 20: a rotor; 21a, 21 b: a bearing; 30: a bracket; 35: a hot melt connection; 40: molding a stator; 41: a molded resin portion; 42: a stator; 43: a stator core; 44: an insulating section; 45: a coil; 46: a substrate; 47: a magnetic sensor; 49: a hollow part; 50: a stator assembling portion; 51: a substrate pressing member; 54: a terminal; 55: a terminal insertion hole; 100: an electric motor; 101: the 1 st magnetic pole inter part; 111: the 2 nd interpolar portion; 300: an air conditioner; 310: an indoor unit; 320: an outdoor unit; 330: an air blower for outdoor units.
Detailed Description
Hereinafter, a motor and an air conditioner according to an embodiment of the present invention will be described in detail with reference to the drawings. The present invention is not limited to the embodiment.
Fig. 1 is a diagram showing a structure of a motor according to embodiment 1 of the present invention, fig. 2 is a perspective view of a stator mounting portion in which a substrate is assembled according to embodiment 1 of the present invention, fig. 3 is a perspective view as viewed from a load side of the stator mounting portion shown in fig. 2, fig. 4 is a side view as viewed from a side opposite to a load side of the substrate shown in fig. 2, and fig. 5 is a side view as viewed from the load side of the substrate shown in fig. 2.
Fig. 6 is a side view of the bearing-assembled rotor shown in fig. 1 as viewed from the load side, fig. 7 is a sectional view taken along line VII-VII shown in fig. 6, and fig. 8 is a side view of the bearing-assembled rotor shown in fig. 1 as viewed from the opposite load side.
Fig. 9 is a side view of the rotor shown in fig. 1 as viewed from the load side, fig. 10 is an X-X sectional view shown in fig. 9, and fig. 11 is a side view of the rotor shown in fig. 1 as viewed from the opposite side to the load.
Fig. 12 is a side view of the rotor magnet as viewed from the load side, fig. 13 is a cross-sectional view taken along line XIII-XIII shown in fig. 12, and fig. 14 is a side view of the rotor magnet shown in fig. 13 as viewed from the opposite side to the load side.
Fig. 15 is a diagram showing the magnetization distribution of the rotor in embodiment 1 of the present invention, and fig. 16 is a diagram showing the induced voltage induced by the coil wound around the stator in embodiment 1 of the present invention and the output waveform of the magnetic sensor. Hereinafter, the structure of the motor according to embodiment 1 will be described with reference to fig. 1 to 16.
The motor 100 shown in fig. 1 includes a molded stator 40, a rotor 20 disposed inside the molded stator 40, and a metal bracket 30 attached to one end portion in the axial direction of the molded stator 40. The motor 100 is a brushless DC motor or a stepping motor.
The molded stator 40 includes a stator 42, a substrate 46 arranged coaxially with the stator 42 and facing the stator 42, and a molded resin portion 41 covering a stator mounting portion 50 shown in fig. 2 in which the substrate 46 is assembled to the stator 42. That is, the molded stator 40 is formed by integrally molding the stator mounting portion 50 with a molding resin that is a material of the molding resin portion 41.
As the molding resin, a thermosetting resin as an unsaturated polyester is used. Since the substrate 46 is generally of a weak structure, low-pressure molding is preferable. Therefore, for the molding, a thermosetting resin such as an unsaturated polyester resin is used.
The stator mounting portion 50 shown in fig. 2 includes: an annular stator 42; a base plate 46 assembled to one axial end of the stator 42; and a substrate pressing member 51 assembled to the substrate 46 and pressing a surface of the substrate 46 opposite to the stator 42.
When the stator mounting portion 50 is inserted into a not-shown molding die and the die is closed, the substrate pressing member 51 abuts against the molding die. By thus abutting the substrate pressing member 51 against the molding die, deformation of the substrate 46 due to the pressure of molding is suppressed. The dropping of the solder joint portion on the substrate 46 due to the deformation of the substrate 46 can be prevented, and the quality can be improved.
The stator 42 includes a stator core 43 formed by laminating electromagnetic steel plates, an insulating portion 44 provided in the stator core 43, and a coil 45 wound around the insulating portion 44.
The insulating portion 44 is formed integrally with the stator core 43 by a thermoplastic resin, or is provided by assembling a separate molded product formed by a thermoplastic resin to the stator core 43. The thermoplastic resin is, for example, polybutylene terephthalate.
The insulating portion 44 is provided with a plurality of projections 52, and the substrate 46 is assembled with the projections 52. The substrate 46 is assembled to the insulating portion 44 by deforming the protrusion 52 by thermal welding. Further, the insulating portion 44 is provided with a plurality of terminals 54 electrically connected to the coil 45.
As shown in fig. 4 and 5, the substrate 46 includes: a plurality of terminal insertion holes 55 formed in the outer peripheral portion of the substrate 46; a plurality of holes 53 formed in the outer periphery of the substrate 46 and fitted into the plurality of protrusions 52 provided in the insulating portion 44 shown in fig. 2.
As shown in fig. 2, the plurality of terminals 54 are inserted into the terminal insertion holes 55 and soldered, respectively, to be electrically connected to the substrate 46. Further, the substrate 46 is assembled to the insulating portion 44 by deforming and thermally melting the distal ends of the projections 52 inserted into the plurality of holes 53.
As shown in fig. 3 and 5, the magnetic sensor 47 is provided on the substrate 46. The magnetic sensor 47 constitutes a sensor circuit that detects the rotational position of the rotor 20. As shown in fig. 1, the magnetic sensor 47 is provided on the substrate 46 so as to face the sensor magnet 11.
The magnetic sensor 47 detects switching of the magnetism generated from the sensor magnet 11, that is, the magnetic flux NS, thereby specifying the position of the rotor 20 in the circumferential direction and outputting a detection signal.
The detection signal is input to the outside of the motor 100 or to a drive circuit, not shown, provided on the substrate 46. When the electric motor 100 is a brushless DC motor, the drive circuit controls energization of the coil 45 based on the relative position of the rotor magnet 10 with respect to the stator 42 using the detection signal. This enables efficient and low-noise driving of the motor 100.
As shown in fig. 1, the rotor shaft 1 is integrally provided to the rotor 20. That is, the rotor shaft 1 is inserted through the shaft hole 48 of the rotor 20. The pair of bearings 21a and 21b are assembled to the rotor shaft 1. The rotor 20 with the bearings 21a and 21b assembled therein is inserted into the hollow portion 49 provided in the molded stator 40.
The bearing 21a is disposed on the opposite side of the rotor 20 from the load, and is supported by the molded resin portion 41. The bearing 21b is disposed on the load side of the rotor 20 and supported by the bracket 30.
As shown in fig. 6 to 14, the rotor 20 includes: a rotor shaft 1; an annular rotor magnet 10 disposed coaxially with the rotor shaft 1 on the outer peripheral surface of the rotor shaft 1 and formed by molding a molding material; and an annular sensor magnet 11 disposed coaxially with the rotor shaft 1 and assembled to one end of the rotor magnet 10 in the axial direction of the rotor shaft 1.
The rotor magnet 10, which is a main magnet, has a 1 st end surface 10a on the opposite side of the load and a 2 nd end surface 10b on the load side. Hereinafter, the axial direction of the rotor shaft 1 is simply referred to as "axial direction". The axial direction of the rotor shaft 1 is the axial direction of the rotor magnet 10 and is also the axial direction of the sensor magnet 11.
The rotor magnet 10 has a plurality of magnetic poles in which N-poles as the 1 st magnetic pole and S-poles as the 2 nd magnetic pole are alternately arranged in the circumferential direction. The 1 st and 2 nd magnetic poles are oriented with polar anisotropy, or the 1 st and 2 nd magnetic poles are oriented in the radial direction of the stator 42.
The sensor magnet 11 is disposed coaxially with the rotor magnet 10, facing the rotor magnet. The sensor magnet 11 has a plurality of magnetic poles in which N poles as 3 rd magnetic poles and S poles as 4 th magnetic poles are alternately arranged in the circumferential direction, wherein the 3 rd magnetic pole has the same polarity as the 1 st magnetic pole, and the 4 th magnetic pole has the same polarity as the 2 nd magnetic pole. The 3 rd and 4 th magnetic poles are oriented in the axial direction of the stator 42. By separating the sensor magnet 11 from the rotor magnet 10, the orientation of the sensor magnet 11 can be changed to the orientation direction of the rotor magnet 10, and the sensor magnet can be oriented in the axial direction. Therefore, the magnetic flux of the sensor magnet 11 is directed in the direction perpendicular to the magnetic sensor 47, that is, in the sensitivity direction of the magnetic sensor 47, so that the magnetic sensor 47 can detect the magnetic flux of the sensor magnet 11 with high accuracy. This improves the accuracy of detecting the position of rotor 20, and therefore improves the operating efficiency and performance of motor 100. Further, by separating the sensor magnet 11 from the rotor magnet 10, the magnetic poles of the sensor magnet 11 and the rotor magnet 10 can be shifted and magnetized. As a result, as described later, the positional deviation of the magnetic sensor 47 with respect to the stator 42 in the circumferential direction (rotational direction) is corrected, and the position detection accuracy of the rotor 20 is improved, so that the operating efficiency and performance of the motor 100 are improved. Further, since the magnetic sensor 47 is disposed on the stator 42 so that the magnetic sensor 47 faces the sensor magnet 11 and the sensitivity direction of the magnetic sensor 47 is set to the axial direction, the influence of the leakage magnetic flux of the coil 45 of the stator 42 is reduced, and the position detection accuracy of the rotor 20 is improved, thereby improving the operating efficiency and performance of the motor 100.
A plurality of bases 7 are provided on the 1 st end surface 10a of the rotor magnet 10, and the sensor magnet 11 is placed on the plurality of bases 7. That is, the sensor magnet 11 abuts against the plurality of bases 7.
Further, each base 7 is provided with a protrusion 5, the protrusion 5 passes through a hole 15 provided in the sensor magnet 11, and the sensor magnet 11 is fixed to the rotor magnet 10. At this time, the tip end of the protrusion 5 is thermally welded to form a thermally welded part 35. The height of the heat fusion part 35 is the same as or lower than the height of the detection part 14 of the sensor magnet 11.
The bearing 21a is press-fitted into the rotor shaft 1 until it abuts against the end face of the cylindrical portion 12 of the sensor magnet 11, and the bearing 21b is press-fitted into the rotor shaft 1 until it abuts against the bearing abutting portion 4 of the rotor magnet 10.
The rotor magnet 10 has a two-layer structure, with the back yoke 3 as the 1 st ring layer being the inner layer and the plastic magnet 9 as the 2 nd ring layer being the outer layer. That is, the rotor magnet 10 includes an annular back yoke 3 disposed on the outer peripheral surface of the rotor shaft 1 and an annular plastic magnet 9 disposed on the outer peripheral surface of the back yoke 3.
The back yoke 3 is formed by molding a thermoplastic resin containing soft magnetic powder or ferrite powder. The thermoplastic resin is, for example, polyamide. The back yoke 3 is integrally formed with the rotor shaft 1 on the outer peripheral surface of the rotor shaft 1 and fixed to the rotor shaft 1. The back yoke may be formed by molding a thermoplastic resin containing both soft magnetic powder and ferrite powder.
The plastic magnet 9 is formed by molding a thermoplastic resin containing a rare-earth magnet powder. The plastic magnet 9 is integrally molded with the back yoke 3 on the outer peripheral surface of the back yoke 3. A knurling 2 is provided on the outer peripheral surface of the central portion of the rotor shaft 1 in the axial direction. The knurls 2 prevent the rotor shaft 1 from being detached from the back yoke 3 and prevent the rotor shaft 1 from rotating.
The outer periphery of the back yoke 3 is formed in a corrugated shape, and the unevenness is repeated in the circumferential direction. The magnetic poles of the rotor magnet 10 are set in association with the irregularities on the outer periphery of the back yoke 3. The back yoke 3 can be magnetized by arranging magnetic poles in the corrugated recesses on the outer periphery thereof and arranging magnetic poles between the magnetic poles in the projections. The back yoke 3 may be oriented such that magnetic poles are arranged on the corrugated convex portions on the outer periphery of the back yoke 3 and magnetic poles are arranged between the concave portions.
The back yoke 3 includes a cylindrical portion 8 on an end surface on the substrate 46 side, and a bearing contact portion 4 on an end surface on the opposite side from the substrate 46. Specifically, the cylindrical portion 8 is provided around the shaft hole 48 at the end surface of the back yoke 3 on the side of the base plate 46, and protrudes to the side of the base plate 46 at a predetermined height. The cylindrical portion 8 is provided radially inward of the back yoke 3 with respect to the base 7.
The cylindrical portion 8 receives the bearing 21a via the sensor magnet 11. The bearing contact portion 4 is provided around the shaft hole 48 at the end face of the back yoke 3 opposite to the end face provided with the cylindrical portion 8, and protrudes to the side opposite to the base plate 46 at a predetermined height.
The inner diameter of the cylindrical portion 8 is larger than the outer diameter of the rotor shaft 1 from the end surface of the cylindrical portion 8 to a certain depth. This suppresses the occurrence of burrs during molding of the back yoke 3, thereby improving the quality.
The end surface of the back yoke 3 on which the cylindrical portion 8 is provided forms a part of the 1 st end surface 10a of the rotor magnet 10. A plurality of bases 7 and projections 5 are provided on the end surface of the back yoke 3, and the projections 5 are provided on the bases 7 and extend in the axial direction from the bases 7.
The plurality of projections 5 are arranged uniformly in the circumferential direction of the back yoke 3. In addition, the plurality of projections 5 are equal in position to each other in the radial direction. The plurality of protrusions 5 are equal in height to each other. The height of the protrusion 5 is shorter than the axial length from one end of the rotor shaft 1 on the protrusion 5 side to the end surface of the base 7. In the example of the figure, 3 bases 7 are formed, and 3 protrusions 5 are also formed.
The plurality of bases 7 are formed integrally with the cylindrical portion 8. The plurality of bases 7 radially extend outward from the cylindrical portion 8. The height of the end surface of the cylindrical portion 8 is equal to the height of the end surface of the base 7, and these end surfaces are flush with each other. The base 7 and the cylindrical portion 8 serve as a mounting surface for the sensor magnet 11, and the sensor magnet 11 is positioned in the axial direction by these surfaces.
The number of the protrusions 5 is not limited to the illustrated example, and may be a plurality of protrusions other than 3 or 1. However, since the protrusion 5 is used for assembling the sensor magnet 11, a plurality of protrusions are generally provided for balancing.
One or more bases 7 may be provided depending on the number of the projections 5. Further, the base 7 may be formed separately from the cylindrical portion 8. In this case, a plurality of bases 7 may be connected to form a single base, and the number of bases 7 may be set separately from the number of projections 5.
The protrusion 5 can be formed in a peripheral polygonal shape. In the example of the figure, the protrusion 5 has a peripheral octagonal shape. On the other hand, the hole 15 has a circular shape.
The sensor magnet 11 can be fixed to the back yoke 3 by inserting the protrusion 5 through the hole 15 and thermally welding the tip end portion of the protrusion 5. Here, when the projection 5 is formed in a cylindrical shape, a gap is required between the projection 5 and the hole 15 in order to insert and pass the projection 5, and the gap becomes a factor of backlash, and the axial centers of the rotor magnet 10 and the sensor magnet 11 are deviated.
In embodiment 1, when the protrusion 5 is formed in the outer peripheral polygonal shape and the protrusion 5 is inserted into the hole 15, the protrusion 5 and the hole 15 are designed in size such that the corners of the outer periphery of the protrusion 5 are cut off at the edge of the hole 15. Thus, the sensor magnet 11 can be aligned by eliminating the play in the state where the protrusion 5 is inserted into the hole 15. Therefore, concentricity between the rotor magnet 10 and the sensor magnet 11 is improved, and the position detection accuracy of the rotor 20 is improved, so that the operating efficiency and the performance of the motor 100 are improved.
Further, a gate 6 is formed in the protrusion 5, and this gate 6 is used as a resin injection port when molding the back yoke 3. The back yoke 3 is molded by injecting a thermoplastic resin containing soft magnetic powder or ferrite powder from the gate 6.
In general, when a gate provided on an end surface of the back yoke 3 is cut, a cut portion may protrude from the end surface to cause a defect, and therefore a recess is provided around the gate so as to avoid the cut portion from protruding from the end surface, thereby suppressing the defect.
However, if the back yoke 3 is provided with the recess, the amount of the magnet of the rotor magnet 10 is reduced, and the rotor magnet 10 becomes unbalanced, so that there is a possibility that the magnetic force is decreased, the distortion rate of the magnetic flux density distribution is deteriorated, and the efficiency and performance of the motor 100 are deteriorated.
In embodiment 1, since the gate 6 is provided in the projection 5 and the tip of the projection 5 is crushed by thermal welding, quality defects due to the projection of the cut portion of the gate 6 do not occur, and a recess does not need to be provided in the rotor magnet 10, so that the efficiency and performance of the motor 100 can be suppressed from being degraded.
Further, in embodiment 1, since the protrusion 5 is provided on the base 7, even if the sensor magnet 11 is pressed when the distal end portion of the protrusion 5 is thermally welded, the warpage and deformation of the sensor magnet 11 are suppressed by the base 7, and the quality of the assembled product is improved.
Further, in embodiment 1, the height of the protrusion 5 is set to be shorter than the axial length from the end of the rotor shaft 1 on the protrusion 5 side to the end surface of the base 7. Therefore, when the sensor magnet 11 is assembled to the rotor magnet 10, the rotor shaft 1 is inserted into the shaft hole 13 of the sensor magnet 11 before the protrusion 5 is inserted into the hole 15 of the sensor magnet 11. Therefore, the sensor magnet 11 and the rotor magnet 10 are centered, and the assembly is easy.
Further, after the back yoke 3 is molded, the gate 6 is left on the projection 5 as a trace of the gate. The gate mark is a mark indicating the position of the gate 6 at the time of injection molding, and a mark corresponding to the gate 6 is formed on the protrusion 5.
The end face of the back yoke 3 opposite to the sensor magnet 11 forms a part of the 2 nd end face 10b of the rotor magnet 10, and a plurality of recesses 16 are provided in the end face of the back yoke 3. That is, a plurality of recesses 16 are provided on the end surface of the back yoke 3 on which the bearing contact portion 4 is provided.
In the illustrated example, the number of the recesses 16 is 6, and the number of the protrusions 5 is 3 or more. The plurality of recesses 16 are constituted by a plurality of recesses 16a and 1 recess 16 b.
The plurality of recesses 16a are equal in distance in the radial direction from the axis of the back yoke 3 and in depth from the end surface of the back yoke 3.
The distance in the radial direction from the axis of the back yoke 3 and the depth from the end surface of the back yoke 3 of the recess 16b are different from those of the plurality of recesses 16 a.
The shaft of the back yoke 3 is the shaft of the rotor shaft 1 and is also the shaft of the rotor magnet 10. The plurality of recesses 16a are arranged uniformly in the circumferential direction of the back yoke 3.
In the illustrated example, the number of the recesses 16a is 5. Specifically, the depth of the recess 16a is larger than the depth of the recess 16 b. The recess 16a is disposed radially inward of the recess 16 b.
By providing a plurality of recesses 16 in the end surface of the back yoke 3 opposite to the end surface of the back yoke 3 provided with the projections 5, as described in detail below, sticking of the back yoke 3 to the mold when the mold is opened is suppressed.
The back yoke 3 is molded by injecting a molding material from a gate 6 formed with a protrusion 5. In this case, the protrusion 5 is disposed on a fixed-side mold, not shown. Therefore, the molding pressure is applied to the protrusion 5 at the maximum, the friction force between the protrusion 5 and the fixed-side mold increases, and the mold release force of the fixed-side mold increases.
When the mold release force of the fixed-side mold is larger than that of the movable-side mold, not shown, the protrusion 5 is easily attached to the fixed-side mold during mold opening, and when the protrusion 5 is actually attached to the fixed-side mold, continuous molding is difficult, and productivity is lowered. Further, when the molded article attached to the fixed-side mold is removed, the protrusion 5 may be bent or the protrusion 5 may be cracked, and a defective product may be transferred to a subsequent step, resulting in a quality problem.
When the mold is opened, the molding grade is set in the movable mold, and the molded product is projected by the ejector pin provided in the movable mold and taken out, thereby enabling continuous molding. The suppression of sticking to the fixed-side mold generally increases the mold-drawing taper.
In the illustrated example, the outer periphery of the protrusion 5 is tapered so as to increase from the gate 6 side to the base 7 side, but the draft taper can be increased by making the outer diameter of the protrusion 5 on the gate 6 side smaller.
This can suppress the mold release force of the fixed-side mold, and can suppress sticking of the protrusion 5 to the fixed-side mold.
However, the sensor magnet 11 is fixed to the rotor magnet 10 by inserting the protrusion 5 through the hole 15 of the sensor magnet 11 and thermally welding the tip end portion. Therefore, if the taper of the protrusion 5 is increased, the hole 15 of the sensor magnet 11 may be loosened, and the alignment may be insufficient.
Therefore, in embodiment 1, the plurality of recesses 16 are provided on the end surface opposite to the end surface on which the protrusion 5 is provided, so that the friction force between the movable mold and the molded article is increased, and the mold release force of the movable mold becomes larger than that of the fixed mold.
This suppresses sticking of the back yoke 3 to the fixed-side mold during mold opening. That is, without increasing the draft taper shape of the projection 5 formed with the gate 6, a plurality of recesses 16 are provided on the end surface opposite to the end surface provided with the projection 5.
Further, the back yoke 3 can be continuously molded, so that the productivity and the cost can be reduced, and the quality can be improved because the projection 5 can be prevented from being bent or cracked.
The number and depth of the recesses 16 are set according to the mold release force of the fixed-side mold, but the mold release force of the movable-side mold can be increased by setting the number of the recesses 16 to be equal to or greater than the number of the protrusions 5. The number and depth of the recesses 16 can be set so that the sum of the surface areas of the plurality of recesses 16 is equal to or greater than the sum of the surface areas of the plurality of protrusions 5.
In the illustrated example, the cross-sectional shape of the recess 16 is a circle, but the cross-sectional shape is not limited to this, and other shapes are also possible. For example, the cross-sectional shape of the recess 16 may be a polygonal shape, as in the case of the protrusion 5. The cross-sectional shape is a shape of a cross section perpendicular to the axial direction.
Further, by providing a plurality of convex portions instead of the plurality of concave portions 16 on the end surface opposite to the end surface provided with the protrusion 5, the mold release force of the movable mold can be increased. However, in this case, the convex shape of the convex portion increases the amount of resin required for molding, which leads to an increase in cost.
The recess 16 is disposed outside the bearing contact portion 4 and radially inside the outer periphery of the back yoke 3 at a predetermined distance. This ensures a sufficient magnetic path for obtaining the magnetic force of the rotor magnet 10 by ensuring the radial thickness of the back yoke 3 without being obstructed by the recess 16. In particular, the plurality of recesses 16a are arranged radially further toward the outer peripheral side of the bearing contact portion 4 than the outer periphery of the back yoke 3.
In the illustrated example, the number of the recesses 16 is larger than the number of the protrusions 5, but the number of the recesses 16 may be equal to the number of the protrusions 5.
When the number of the recesses 16 is equal to the number of the protrusions 5, the recesses 16 can be disposed at positions axially facing the protrusions 5. That is, 1 or more recesses 16 and 1 or more protrusions 5 can be associated one-to-one, and the distances between the recesses 16 and the protrusions 5 that are associated with each other in the circumferential direction and the radial direction can be made equal.
The circumferential direction and the radial direction are the circumferential direction and the radial direction of the back yoke 3. The distance in the radial direction is the length in the radial direction from the axis of the back yoke 3.
In addition, in the case where the number of the recesses 16 is equal to the number of the protrusions 5, it is also possible to align only the positions of the recesses 16 in the circumferential direction with the positions of the protrusions 5 in the circumferential direction. The number of the recesses 16a and the number of the protrusions 5 can be equal, 1 or more recesses 16a and 1 or more protrusions 5 can be associated with each other in a one-to-one manner, and the positions of the corresponding recesses 16a and protrusions 5 in the circumferential direction and the radial direction can be equal.
In addition, in the case where the number of the recesses 16a is equal to the number of the protrusions 5, it is also possible to align only the positions of the recesses 16a in the circumferential direction with the positions of the protrusions 5 in the circumferential direction.
In addition, when the number of the recesses 16 is larger than the number of the protrusions 5, the recesses 16 can be arranged uniformly in the circumferential direction of the back yoke 3. With this arrangement, the mold release force of the recess 16 efficiently acts on the mold release force of the protrusion 5 at the time of mold opening, and the sticking of the back yoke 3 to the fixed-side mold can be stably suppressed.
Further, the back yoke 3 can be balanced. In addition, when the number of the recesses 16a is larger than the number of the protrusions 5, the recesses 16a can be arranged uniformly in the circumferential direction of the back yoke 3. In this case, the same effect is also obtained.
The depth of the recess 16b is shallower than the plurality of recesses 16 a. The recess 16b is disposed radially outward of the plurality of recesses 16 a. Thereby, the recess 16b is easily distinguished from the plurality of recesses 16 a. Therefore, such a concave portion 16b can be used for positioning in the molding process of the plastic magnet 9 or the magnetizing process of the rotor magnet 10.
The positioning recess 16b can be formed by a tip. Specifically, the back yoke 3 may be molded in a state where a pin, not shown, provided in the movable mold is disposed inside the mold by the length of the recess 16 b. Therefore, the die is simplified, and the manufacturing cost of the die is reduced.
Further, a part or all of the plurality of concave portions 16a may be formed by the tip.
The rotor magnet 10 is formed by providing the back yoke 3 in a mold and integrally molding the plastic magnet 9 on the outer peripheral surface of the back yoke 3. At this time, the wave shape of the outer periphery of the back yoke 3 is transferred to the inner periphery of the plastic magnet 9, and the outer periphery of the back yoke 3 and the inner periphery of the plastic magnet 9 are engaged with each other, so that the wave shape of the inner periphery of the plastic magnet 9 becomes a rotation stop.
Further, since the outer periphery of the back yoke 3 is formed in a corrugated shape to form a magnetic path, the magnetic flux density distribution can be adjusted.
When the back yoke 3 is provided in a mold for molding the plastic magnet 9, for example, when the end surface side of the cylindrical portion 8 provided with the back yoke 3 is inserted into the movable-side mold, the corrugated shape of the outer periphery of the back yoke 3 needs to be aligned with the protrusion 5 at a predetermined position of the movable-side mold.
In this case, 3 protrusions 5 are arranged uniformly in the circumferential direction, and no position is selected for installation in the movable-side mold, but the number of the protrusions 5 is not generally symmetrical with respect to the arrangement of the protrusions 5 because the corrugated shape of the outer periphery of the back yoke 3 depends on the number of poles of the rotor magnet 10, and therefore the number of the protrusions and recesses in the corrugated shape is not a multiple of the number of the protrusions 5. Therefore, it is necessary to align the mold for molding the plastic magnet 9 with the position of the back yoke 3.
Since it is difficult to perform positioning by the projection 5 which is not visible in the setting, the back yoke 3 is positioned and set in the mold with reference to the recess 16b provided in the end surface opposite to the end surface on which the projection 5 is provided. This facilitates positioning of the back yoke 3, and improves productivity.
Further, the magnetic orientations of the back yoke 3 and the plastic magnet 9 are precisely aligned, so that the magnetic characteristics of the rotor magnet 10 are stabilized, the performance of the motor 100 is improved, and the sound and vibration of the motor 100 are reduced.
The concave portion 16b can be used not only for positioning the mold for molding the plastic magnet 9 with respect to the back yoke 3, but also for positioning in the magnetization process of the rotor magnet 10. That is, when the rotor magnet 10 is inserted into a magnetizing yoke, not shown, the recess 16b can be used for alignment between the rotor magnet 10 and the magnetizing yoke. This improves and stabilizes the magnetization accuracy, and improves the performance of the motor 100.
Further, the rotor magnet 10 is configured such that the plastic magnet 9 is molded on the outer peripheral surface of the back yoke 3, but the rotor magnet 10 may be configured to have a 1-layer structure, and the entire rotor magnet 10 may be configured only by the plastic magnet 9. Even in this case, the concave portion 16b can be used for positioning in the magnetization step.
As shown in fig. 15, in the rotor magnet 10, the N-poles and the S-poles are alternately magnetized in the circumferential direction on the outer circumferential side of the rotor magnet 10. In the sensor magnet 11, the same magnetic poles as those of the rotor magnet 10 are magnetized in the circumferential direction on the surface facing the substrate 46.
The 1 st interpole magnetic pole portion 101 is the 1 st position where the adjacent N pole and S pole of the rotor magnet 10 are switched. The 2 nd inter-magnetic-pole portion 111 is the 2 nd position where the N pole and the S pole of the sensor magnet 11 adjacent to each other are switched.
The rotor magnet 10 and the sensor magnet 11 are magnetized by adding a phase difference a for correcting a variation in the installation position of the magnetic sensor between the 1 st inter-magnetic-pole part 101 and the 2 nd inter-magnetic-pole part 111. The reason for providing the phase difference a will be described below.
The position detection of the rotor 20 is affected by the magnetized positions of the magnetic poles of the rotor magnet 10 and the sensor magnet 11, and the position of the magnetic sensor 47 in the circumferential direction of the stator 42. That is, an error occurs in the detected position of the rotor 20 due to a variation in the magnetized position of the rotor 20 and a variation in the installation position of the magnetic sensor 47 on the stator. Hereinafter, this error is referred to as a position detection error of the rotor 20.
The position detection error of the rotor 20 becomes a problem in achieving high efficiency of the motor 100. Therefore, in order to drive the motor 100 with high efficiency and low noise, it is necessary to reduce a position detection error of the rotor 20 when the rotor 20 rotates.
In order to reduce the position detection error of the rotor 20, 3 countermeasures are required.
The 1 st countermeasure is to improve the phase accuracy between the magnetic poles of the rotor magnet 10 and the magnetic poles of the sensor magnet 11 in the rotor 20.
The 2 nd countermeasure is to improve the accuracy of the installation position of the magnetic sensor 47 provided on the substrate 46.
The 3 rd countermeasure is to improve the accuracy of assembling the projection 52 of the insulating portion 44 of the stator 42 and the hole 53 of the substrate 46.
However, in the 2 nd countermeasure, the accuracy of the installation position of the magnetic sensor 47 on the substrate 46 varies depending on the installation equipment not shown. In addition, in the 3 rd countermeasure, the accuracy of assembling the projection 52 and the hole 53 varies not only by the position of the gap between the projection 52 and the hole 53 but also by the size of the projection 52 and the hole 53. Therefore, it is difficult to improve the positional accuracy itself of the magnetic sensor 47 in the circumferential direction with respect to the stator 42.
Therefore, in the rotor 20 according to embodiment 1, the magnetic poles of the rotor magnet 10 and the magnetic poles of the sensor magnet 11 are magnetized so as to eliminate a position detection error of the rotor 20 caused by a positional deviation of the magnetic sensor 47 with respect to the stator 42 in the circumferential direction.
The following description will be specifically made with reference to fig. 16.
Fig. 16(a) shows a waveform of an induced voltage induced in the coil 45. Fig. 16(a) shows a phase deviation θ between the zero-crossing point of the induced voltage and the rising edge point of the detection signal shown in fig. 16 (b). The zero crossing point is the point at which the induced voltage switches from positive to negative or vice versa.
Fig. 16(b) shows a waveform of a detection signal output from the magnetic sensor 47 when the reference rotor is combined with the stator 42 that causes a positional deviation of the magnetic sensor 47 with respect to the stator 42.
The waveform of the detection signal in fig. 16(b) changes positively and negatively with reference to the ground level. The reference rotor is a rotor in which the position of the 1 st interpolar portion 101 in the circumferential direction coincides with the phase of the 2 nd interpolar portion 111 in the circumferential direction, or a rotor in which the position of the 1 st interpolar portion 101 in the circumferential direction and the phase of the 2 nd interpolar portion 111 in the circumferential direction are known values.
Fig. 16(c) shows a waveform of a detection signal of the magnetic sensor 47 when the rotor 20 magnetized with the phase difference a is combined with the stator 42 in which the position of the magnetic sensor 47 is deviated.
The phase deviation θ between the rising edge point of the detection signal of the magnetic sensor 47 shown in fig. 16 and the zero-cross point at which the induced voltage changes from negative to positive is caused by a positional deviation of the magnetic sensor 47 with respect to the stator 42 in the circumferential direction. The phase deviation θ is assumed to be, for example, a phase deviation in the positive rotational direction of the rotor.
The phase deviation θ is a position detection error of the rotor 20. In order to correct the position detection error, that is, to cancel the phase shift θ, it is necessary to measure the phase shift θ of the magnetic sensor 47 in the circumferential direction (rotational direction) with respect to the stator 42, and it is necessary to combine the rotor 20 that generates the phase shift — θ in the negative rotational direction. The positional deviation of the magnetic sensor 47 in the circumferential direction (rotational direction) with respect to the stator 42 is derived from the induced voltage induced by the coil 45 of the stator 42 and the output of the magnetic sensor 47 of the substrate 46. Specifically, the rotor 20 as a reference, for example, a rotor in which the phases of the magnetic poles of the rotor magnet 10 and the sensor magnet 11 are matched or the phase difference is known, is combined with the molded stator 40, and the motor is temporarily assembled. Then, the rotor 20 serving as a reference is rotated by an external force, the induced voltage induced by the coil 45 is compared with the waveform of the output of the magnetic sensor 47 of the substrate 46, and the phase difference between the positive and negative switching position (ground level) of the induced voltage and the rising edge or the falling edge of the output of the magnetic sensor 47 is the positional deviation of the molded stator 40, that is, the positional deviation of the magnetic sensor 47 with respect to the stator 42 in the circumferential direction (rotational direction).
Hereinafter, a process of correcting the phase detection error of the rotor 20 will be described specifically.
(1) First, the reference rotor is combined with the molded stator 40, and the motor is temporarily assembled.
(2) The rotor shaft of the reference rotor is rotated by an external force in a state where the motor is temporarily assembled. At this time, the induced voltage induced in the coil 45 and the waveform of the detection signal output from the magnetic sensor 47 of the substrate 46 are measured. The induced voltage waveform and the detection signal waveform are measured as shown in fig. 16(a) and (b).
(3) A phase difference A corresponding to the phase deviation-theta is derived from the detection signal and the induced voltage obtained by the measurement. Then, the rotor magnet 10 and the sensor magnet 11 are magnetized with a phase difference a. In the example of fig. 15, the 2 nd inter-magnetic-pole portion 111 is offset by a certain amount clockwise with respect to the position of the 1 st inter-magnetic-pole portion 101 in the circumferential direction. In this way, the rotor magnet 10 and the sensor magnet 11 are magnetized by adding the phase difference a for correcting the variation in the installation position of the magnetic sensor between the 1 st inter-magnetic-pole part 101 and the 2 nd inter-magnetic-pole part 111.
(4) The rotor 20 thus magnetized is combined with the molded stator 40 to complete the motor 100.
By using the rotor 20 with the phase difference a, a position detection error of the rotor 20 is corrected, and the rotational position is detected with high accuracy. As a result, motor 100 can be driven with high efficiency and low noise.
Further, although embodiment 1 illustrates a molded motor molded with a thermosetting resin, the same effects as those of embodiment 1 can be obtained even in a motor in which the stator mounting portion 50 and the rotor 20 are combined with a housing obtained by processing a metal plate.
In embodiment 1, the sensor magnet 11 is fixed to the end face of the rotor magnet 10, but the sensor magnet 11 may be fixed to the rotating shaft so as to be separated from the rotor magnet 10. This allows the circumferential position to be adjusted when the sensor magnet 11 is mounted on the rotating shaft. Therefore, the magnitude of the phase difference a between the magnetized sensor magnet 11 and the rotor magnet 10 can be finely adjusted, and the position of the magnetic sensor 47 on the substrate 46 in the circumferential direction can be accurately corrected.
As described above, the motor 100 according to embodiment 1 includes the stator 42, the rotor magnet 10, the sensor magnet 11, the substrate 46, and the magnetic sensor 47, and the rotor magnet 10 and the sensor magnet 11 are magnetized with the phase difference a added to correct the position of the magnetic sensor 47 on the substrate 46 in the circumferential direction in the motor 100. With this configuration, the position detection error of the rotor 20 is corrected, and the position of the rotor 20 is detected with high accuracy. Therefore, the motor 100 can be driven with high efficiency and low noise, and the work efficiency and quality of the motor 100 can be improved.
In embodiment 1, since the plurality of recesses 16 are provided on the end surface of the back yoke 3 in the axial direction, which is opposite to the end surface on which the plurality of protrusions 5 are provided, and the number of recesses 16 is equal to or greater than the number of protrusions 5, the sticking of the back yoke 3 to the fixed-side mold is suppressed at the time of molding the back yoke 3, and the back yoke 3 can be continuously molded, thereby improving the productivity of the back yoke 3. Furthermore, in the continuous molding of the back yoke 3, the occurrence of bending or cracking of the protrusions 5 is suppressed, and the quality of the back yoke 3 is improved. Thus, improvement in productivity, improvement in quality, and reduction in cost of the motor 100 can be achieved.
In embodiment 1, the number of projections 5 is set to be plural, and the number of recesses 16 is set to be plural, which is equal to or greater than the number of projections 5, but it is also possible to set the number of projections 5 to be 1, and the number of recesses 16 to be equal to or greater than 1. Even when the number of the recesses 16 is 1 or more regardless of the number of the protrusions 5, the effect of suppressing the sticking of the back yoke 3 to the fixed-side mold at the time of molding the back yoke 3 can be obtained. Further, in embodiment 1, the gates 6 are provided on the plurality of projections 5, respectively, but the gates 6 may be provided on a part of the plurality of projections 5.
In embodiment 1, since the depth of one recess 16b of the plurality of recesses 16 from the 2 nd end surface 10b of the rotor magnet 10 is set to be different from the depth of the recess 16a of the plurality of recesses 16, the recess 16b can be easily distinguished from the recess 16a, and can be used as a positioning in the molding step of the plastic magnet 9 and the magnetizing step of the rotor 20. This improves and stabilizes productivity and magnetization accuracy, and improves productivity, quality, performance, and cost of the motor 100.
In general, by providing that at least 1 of 1 recess 16b out of the plurality of recesses 16 is different from each of the other recesses 16a in the radial distance from the axis of the rotor magnet 10, the depth from the 2 nd end face 10b of the rotor magnet 10, and the cross-sectional shape perpendicular to the axial direction, the recess 16b can be easily distinguished from the recess 16a, and can be used as a positioning in the molding step of the plastic magnet 9 and the magnetization step of the rotor 20.
Further, since the recess 16b may be distinguished from the recess 16a in order to use the recess 16b as a positioning member, it may be distinguished from the above by a shape or a radius other than a cross-sectional shape perpendicular to the axial direction. Here, the shape other than the cross-sectional shape perpendicular to the axial direction is, for example, a cross-sectional shape including the axial direction. In this case, the depth from the 2 nd end face 10b of the rotor magnet 10 and the cross-sectional shape perpendicular to the axial direction are easily recognized.
In addition, the recess 16 for positioning may be plural. In general, when at least 1 of the plurality of recesses 16 differs from each of the other recesses 16 in at least 1 of the distance, shape, depth, and radius from the shaft in the radial direction, at least 1 of the plurality of recesses 16 can be used as a positioning in the molding step of the plastic magnet 9 and the magnetizing step of the rotor 20. For example, in fig. 6, two recesses 16b can be provided, and the two recesses 16b can be used for positioning.
In embodiment 1, the protrusion 5 of the rotor magnet 10 is inserted through the hole 15 of the sensor magnet 11, the sensor magnet 11 is brought into contact with the base 7, and the tip of the protrusion 5 is thermally welded, whereby the sensor magnet 11 is fixed to the rotor magnet 10 and the gate 6 for molding is provided on the protrusion 5.
In this way, since the distal end portion of the projection 5 provided with the gate 6 is thermally welded, the projection of the cut portion of the gate 6 disappears, and defects such as contact of the projection of the cut portion with another portion or discharge of the resin powder from the cut portion can be suppressed.
Further, it is not necessary to provide a recess for suppressing the protrusion of the cut portion on the end surface of the rotor magnet 10 as in the conventional case. Therefore, the decrease in magnetic force is suppressed, and the deterioration of the distortion rate of the magnetic flux density distribution is also suppressed, achieving an improvement in the operating efficiency and performance of the motor 100.
In embodiment 1, the tip end portion of the protrusion 5 is thermally welded, and the sensor magnet 11 is fixed to the rotor magnet 10. Since the sensor magnet 11 is mechanically fixed to the rotor magnet 10 in this way, the reliability of assembly is improved.
In addition, since the sensor magnet 11 can be fixed to the rotor magnet 10 by such a simple process, the cost can be reduced. Further, since the height of the heat fusion part 35 is equal to or lower than the height of the detection part 14 of the sensor magnet 11, the heat fusion part 35 does not contact the molded stator when the motor is mounted, and the reliability of assembly is improved.
In embodiment 1, since the protrusion 5 is provided on the base 7, even if the sensor magnet 11 is pressed when the protrusion 5 is thermally melted, the base 7 suppresses the lifting and deformation of the sensor magnet 11, and the quality of assembly is improved.
Fig. 17 is a diagram showing an example of the structure of an air conditioner according to embodiment 2 of the present invention. The air conditioner 300 includes indoor units 310 and an outdoor unit 320 connected to the indoor units 310. The indoor unit 310 is mounted with an indoor fan, not shown, and the outdoor unit 320 is mounted with an outdoor fan 330.
The motor 100 of embodiment 1 is used as a drive source of the outdoor fan 330 and the indoor fan. By using the motor 100 for the outdoor fan 330 and the indoor fan, which are main components used in the air conditioner 300, the air conditioner 300 having improved performance and quality can be obtained.
In the air-conditioning apparatus 300 according to embodiment 2, the motor 100 according to embodiment 1 is provided in at least one of the indoor unit 310 and the outdoor unit 320. Further, motor 100 according to embodiment 1 can also be mounted on an electric device other than an air conditioner, and in this case, the same effects as those of the present embodiment can be obtained.
The configurations described in the above embodiments are merely examples of the contents of the present invention, and may be combined with other known techniques, and some of the configurations may be omitted or modified within a range not departing from the gist of the present invention.
Claims (8)
1. An electric motor is provided with:
an annular stator;
a ring-shaped rotor magnet disposed inside the stator coaxially with the stator, the rotor magnet having a plurality of magnetic poles in which a 1 st magnetic pole and a 2 nd magnetic pole different from the 1 st magnetic pole are alternately arranged in a circumferential direction of the rotor;
a ring-shaped sensor magnet that is disposed coaxially with the rotor magnet and faces the rotor magnet, and that has a plurality of magnetic poles in which a 3 rd magnetic pole having the same polarity as the 1 st magnetic pole and a 4 th magnetic pole having the same polarity as the 2 nd magnetic pole are alternately arranged in a circumferential direction of the rotor; and
a magnetic sensor provided opposite to the sensor magnet and detecting a rotational position of the sensor magnet,
the position of the 1 st magnetic pole and the 1 st magnetic pole of the adjacent 2 nd magnetic pole is the 1 st position,
the position of the adjacent 2 nd magnetic pole between the 3 rd magnetic pole and the 4 th magnetic pole is the 2 nd position,
the rotor magnet and the sensor magnet are magnetized by adding a phase difference that reduces a variation in the installation position of the magnetic sensor between the 1 st position and the 2 nd position.
2. The motor according to claim 1, wherein,
in the sensor magnet, the 3 rd magnetic pole and the 4 th magnetic pole are oriented in an axial direction of the rotor.
3. The motor according to claim 1, wherein,
the sensor magnet is disposed apart from the rotor magnet.
4. The motor according to claim 2, wherein,
the sensor magnet is disposed apart from the rotor magnet.
5. The motor according to any one of claims 1 to 4,
the phase difference is derived from a detection signal output from the magnetic sensor and an induced voltage induced by a coil wound around the stator.
6. The motor according to any one of claims 1 to 4,
the phase difference is derived from a detection signal output from the magnetic sensor when a reference rotor disposed in the stator rotates and an induced voltage induced by a coil wound around the stator,
the reference rotor is a rotor in which the position in the circumferential direction of the 1 st inter-magnetic-pole portion coincides with the phase in the circumferential direction of the 2 nd inter-magnetic-pole portion.
7. The motor according to any one of claims 1 to 4,
the phase difference is derived from a detection signal output from the magnetic sensor when a reference rotor disposed in the stator rotates and an induced voltage induced by a coil wound around the stator,
the reference rotor is a rotor in which the position of the 1 st inter-magnetic-pole portion in the circumferential direction and the phase of the 2 nd inter-magnetic-pole portion in the circumferential direction are known values.
8. An air conditioner comprising the motor according to any one of claims 1 to 7 in at least one of an indoor unit and an outdoor unit.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/JP2015/079038 WO2017064767A1 (en) | 2015-10-14 | 2015-10-14 | Electric motor and air conditioner |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN108028588A CN108028588A (en) | 2018-05-11 |
| CN108028588B true CN108028588B (en) | 2020-06-19 |
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| JP (1) | JP6381821B2 (en) |
| CN (1) | CN108028588B (en) |
| WO (1) | WO2017064767A1 (en) |
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| CA3166273A1 (en) * | 2020-01-29 | 2021-08-05 | Tien PHAN | Motor having integrated actuator with absolute encoder and methods of use |
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| JPH118960A (en) * | 1997-06-13 | 1999-01-12 | Matsushita Electric Ind Co Ltd | Magnetic pole shifting jig and manufacture of rotor using the same |
| JP2003289653A (en) * | 2002-03-27 | 2003-10-10 | Sony Corp | Manufacturing method and device for servo motor |
| CN1462363A (en) * | 2001-05-11 | 2003-12-17 | 索尼公司 | Servo actuator and position sensor thereof |
| JP2004120817A (en) * | 2002-09-24 | 2004-04-15 | Kayaba Ind Co Ltd | Rotor and manufacturing method thereof |
| JP2008131678A (en) * | 2006-11-16 | 2008-06-05 | Jtekt Corp | Magnetization method of sensor magnet |
| JP2009033851A (en) * | 2007-07-26 | 2009-02-12 | Keihin Corp | Brushless motor, manufacturing method therefor, and motor manufacturing apparatus |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3188964B2 (en) * | 1993-01-19 | 2001-07-16 | 本田技研工業株式会社 | Rotating magnetic field detector |
| JP2009232551A (en) * | 2008-03-21 | 2009-10-08 | Aisin Aw Co Ltd | Drive and its manufacturing method |
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2015
- 2015-10-14 CN CN201580082985.XA patent/CN108028588B/en active Active
- 2015-10-14 WO PCT/JP2015/079038 patent/WO2017064767A1/en active Application Filing
- 2015-10-14 JP JP2017545032A patent/JP6381821B2/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH118960A (en) * | 1997-06-13 | 1999-01-12 | Matsushita Electric Ind Co Ltd | Magnetic pole shifting jig and manufacture of rotor using the same |
| CN1462363A (en) * | 2001-05-11 | 2003-12-17 | 索尼公司 | Servo actuator and position sensor thereof |
| JP2003289653A (en) * | 2002-03-27 | 2003-10-10 | Sony Corp | Manufacturing method and device for servo motor |
| JP2004120817A (en) * | 2002-09-24 | 2004-04-15 | Kayaba Ind Co Ltd | Rotor and manufacturing method thereof |
| JP2008131678A (en) * | 2006-11-16 | 2008-06-05 | Jtekt Corp | Magnetization method of sensor magnet |
| JP2009033851A (en) * | 2007-07-26 | 2009-02-12 | Keihin Corp | Brushless motor, manufacturing method therefor, and motor manufacturing apparatus |
Also Published As
| Publication number | Publication date |
|---|---|
| JPWO2017064767A1 (en) | 2018-01-18 |
| CN108028588A (en) | 2018-05-11 |
| JP6381821B2 (en) | 2018-08-29 |
| WO2017064767A1 (en) | 2017-04-20 |
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