CN1485862A - Annular magnet and method for producing the same, and rotor and motor using the same - Google Patents
Annular magnet and method for producing the same, and rotor and motor using the same Download PDFInfo
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- CN1485862A CN1485862A CNA03107412XA CN03107412A CN1485862A CN 1485862 A CN1485862 A CN 1485862A CN A03107412X A CNA03107412X A CN A03107412XA CN 03107412 A CN03107412 A CN 03107412A CN 1485862 A CN1485862 A CN 1485862A
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Abstract
In this ring magnet, a plurality of soft magnetic materials are integrally formed in annular rigid magnetic material of which the easy magnetization direction periodically varies in a circumferential or diametrical direction at a certain interval in the circumferential direction. This manufacturing method of the ring magnet has a forming process of a compound body in which the plurality of soft magnetic materials are disposed at a certain interval in the peripheral direction in the rigid magnetic material particulates disposed in a ring shape, a pressure forming process in which a pressure forming body is formed while the compound body is disposed in a magnetic field, and a sintered process in which the press forming body is sintered.
Description
Technical field
The present invention relates to a kind of novel annular magnet, annular magnet manufacture method, and use the rotor and the motor of annular magnet.
Background technology
(patent documentation 1) TOHKEMY 2000-269062 communique
(patent documentation 2) TOHKEMY 2000-195714 communique
In existing annular magnet, has the circumferential anisotropic magnet that changes continuously in direction of easy axis edge that is recorded in (patent documentation 1), (patent documentation 2).In these known examples, the utilization of magnetic forming process is orientated magnetic by the magnetic field of acquisitions such as coil on magnetic direction, with the unified direction of orientation to magnetic of direction of easy axis.Carry out the orientation of magnetic and be shaped after make its sintering, the direction of easy axis of the magnet behind the sintering is made the utmost point anisotropic magnet with high magnetic characteristic along circumferentially changing.
In the prior art, the annular magnet of the low cogging torque of not shown reluctance torque that satisfies the difference utilized magnetic resistance simultaneously and utmost point anisotropic magnet.In addition, not shown in order to ensure magnetic resistance in the situation of circumferentially arranging the powder of the different magnetic material of magnetic characteristic periodically of integrally formed annular magnet.
Inventors etc. consider as utilizing reluctance torque, then can guarantee slow-revving torque, needing may be used on the motor of the slow-speed of revolution, big torque, so, the structure that utilizes reluctance torque is studied, at the hard magnetic ring soft section is set circumferentially according to research.In addition, the inventor finds, in order to produce such reluctance torque, can be by along circumferentially cutting apart magnet, between magnet and magnet, insert soft magnetic material and realize, but the magnet when existing the magnet machining accuracy to be difficult to guarantee, need bonding operation, the revolution of magnet keeps, the problems such as deviation increase of surface magnetic flux density.
In addition, in the occasion that magnet is divided into each utmost point, per 1 grade form variations makes the surface magnetic flux density wave form varies.When particularly deviation appearred in magnet diameter, the magnetic flux of the tooth front end of stator was extremely different to each.The bonding intensity decreases that makes rotor of magnet and soft magnetic material, or cause the inhomogeneities of magnetic flux to increase by the non-magnetic gap of binding part.
Summary of the invention
The object of the present invention is to provide a kind of manufacture method that satisfies annular magnet at the reluctance torque of poor, the difference of having utilized magnetic resistance that circumferentially has magnetic resistance of annular magnet and extremely anisotropic low cogging torque, annular magnet, and use the rotor and the motor of annular magnet.
Annular magnet of the present invention satisfies the requirement of the low cogging torque (コ ギ Application グ ト Le Network) of the reluctance torque of the difference utilize magnetic resistance and utmost point anisotropic magnet simultaneously.As utilizing reluctance torque, then can guarantee slow-revving torque, may be used on requiring the motor of the slow-speed of revolution and high torque (HT).In order to utilize reluctance torque, need be along the hard magnetic ring soft part circumferentially is set.In order to produce such reluctance torque, can be along circumferentially cutting apart magnet, with high accuracy, easily insert soft magnetic material, the magnet in the time of can solving revolution keeps, the problems such as deviation of surface magnetic flux density between magnet and magnet.
Annular magnet of the present invention is characterised in that: direction of easy axis along in the circumferential or radially periodically variable annular hard magnetic material along circumferential integrally formed at regular intervals a plurality of soft magnetic materials.In addition, the present invention has following feature.
Annular magnet is characterised in that: circumferentially imbed a plurality of soft magnetic materials at regular intervals in direction of easy axis along the outer circumferential side of circumferential or radially periodically variable annular hard magnetic material or at least one side edge of interior all sides, form.
Annular magnet is characterised in that:, form along circumferentially circumferentially imbedding a plurality of soft magnetic materials at regular intervals with the outer circumferential side of the periodically variable annular hard magnetic material of sinusoidal wave shape or at least one side edge of interior all sides in direction of easy axis.
Annular magnet is characterised in that: direction of easy axis along circumferentially with sinusoidal wave shape in the periodically variable annular hard magnetic material along circumferentially imbed at regular intervals a plurality of from interior all sides to the continuous soft magnetic material of outer circumferential side, form.
Annular magnet of the present invention is preferably by sintering integrated above-mentioned hard magnetic material and the soft magnetic material of forming, above-mentioned hard magnetic material and soft magnetic material carry out above-mentioned sintering behind the press molding in magnetic field, the above-mentioned hard magnetic material of above-mentioned soft magnetic material is formed at towards above-mentioned circumferential position in the direction of easy axis that makes progress in week.
Annular magnet manufacture method of the present invention is characterised in that: be included in the formation operation that circumferentially disposes the complex of a plurality of soft magnetic materials at regular intervals in the hard magnetic material powder of loop configurations, above-mentioned complex be orientated in magnetic field and under this state formation press molding body the press molding operation and make above-mentioned press molding body carry out the sintering circuit of sintering.
That is, the present invention through the operation that makes the powder orientation of hard magnetic material by magnetic field, make the powder sintered operation after the orientation, is shaped with the hard magnetic material has the part of soft magnetism feature with being integral, along circumferentially periodically disposing the part that has soft magnetic characteristic.
In addition, outer circumferential side or the part of interior all side of the present invention in the above-mentioned hard magnetic material powder that is configured to annular makes from the high part marshalling of magnetic permeability of the powder forming sintering of soft magnetic material and is shaped.
In addition, make from the part with soft magnetic characteristic of the powder forming sintering of soft magnetic material in the part of the outer circumferential side of above-mentioned ring or interior all sides and circumferentially be shaped by the some cycles marshalling.
The present invention has the powder sintered operation after the powder that uses hard magnetic material and soft magnetic material is made the operation of these powder orientations and made orientation by magnetic field, the edge circumferentially makes the direction of easy axis of the hard magnetic material that forms annular magnet by the sinusoidal wave shape cyclic variation, direction of easy axis at the hard magnetic material of interior all sides of above-mentioned ring has the higher part of magnetic permeability that is made of soft magnetic material towards circumferential circumferential angle position substantially, and the part with soft magnetic characteristic is along circumferentially by the some cycles marshalling.
The present invention makes through the operation of the powder orientation that is made hard magnetic material and soft magnetic material by magnetic field and the direction of easy axis of the hard magnetic material of the annular magnet that the powder sintered operation after making orientation is made circumferentially with the sinusoidal wave shape cyclic variation, the direction of easy axis of the hard magnetic material of above-mentioned ring substantially towards circumferential position the continuous higher part of magnetic permeability that is made of soft magnetic material from interior all sides to outer circumferential side nearby is set, the part with soft magnetic characteristic is along circumferentially by the some cycles marshalling.
In the annular magnet of the powder sintered operation making of the present invention in the operation that is orientated through the powder that makes the hard magnetic material by magnetic field with after making orientation, part with soft magnetic characteristic is integrally formed with the hard magnetic material, by being added to after external magnetic field near direction of orientation makes the ringshaped magnet magnetization, the waveform of surface magnetic flux density becomes sine wave substantially.
The direction of easy axis of the hard magnetic material of best above-mentioned annular circumferentially or is radially being adjusted to cyclic variation above-mentioned magnetic direction, above-mentioned soft magnetic material obtains by in the magnetic field that becomes direction radially or in no magnetic field the soft magnetic material powder being carried out press molding, and above-mentioned soft magnetic material is configured to the direction of easy axis of above-mentioned hard magnetic material towards above-mentioned circumferential position.
In addition, rotor of the present invention is arranged at a periphery with annular magnet, it is characterized in that: above-mentioned annular magnet is made of annular magnet as described above, in addition, or is made of the annular magnet that forms by above-mentioned manufacture method.
In addition, rotating machinery of the present invention has stator and rotating rotor in this stator; Above-mentioned rotor is made of aforesaid rotor; Particularly in motor, nominal torque relatively, cogging torque is below 5%, and is less, has high induced voltage.
Description of drawings
Fig. 1 is the sectional drawing that the radial ringed magnet of soft magnetic material circumferentially periodically is set on extreme portion outer circumferential side edge of the present invention.
Fig. 2 is the sectional drawing that the utmost point anisotropy annular magnet of soft magnetic material circumferentially periodically is set on extreme portion outer circumferential side edge of the present invention.
Fig. 3 is the sectional drawing that the utmost point anisotropy annular magnet of soft magnetic material circumferentially periodically is set in interior all sides of the present invention.
Fig. 4 is the sectional drawing of utmost point anisotropy annular magnet.
Fig. 5 is the sectional drawing of the utmost point anisotropy annular magnet of the annular magnet that soft magnetism portion radially is set in extreme portion of the present invention.
Fig. 6 is the line chart that illustrates along the outer circumferential side surface magnetic flux density that the annular magnet that soft magnetism portion makes circumferentially periodically is set.
Fig. 7 is the line chart of relation that the radially volume fraction of the wave distortion of surface magnetic flux density and soft magnetic material is shown.
Fig. 8 is the line chart of relation that the radially volume fraction of the magnetic permeability of annular magnet and soft magnetic material is shown.
Fig. 9 is the perspective view of the rotator for motor of suitable annular magnet of the present invention.
Figure 10 is the perspective view that is suitable for the rotor of the annular magnet of the present invention that makes the soft magnetic material inclination to axial.
Figure 11 is the sectional drawing of the motor of use rotor of the present invention.
Embodiment
(embodiment 1)
Fig. 1 is the sectional drawing that the annular magnet of soft magnetism portion 3 periodically is set at the extreme portion outer circumferential side of radial ringed magnet of the present invention.The direction of orientation 2 of the direction of easy axis of hard magnetic material 4 shown by dashed lines.The direction of orientation 2 of the direction of easy axis of hard magnetic material 4 is for radially, and the direction vertical with direction of orientation is difficult direction of principal axis.
Hard magnetic material 4 comprises at least by a kind of rare earth metal, Fe (iron) or Co (cobalt), and the compound formed of B (boron) or N (nitrogen) element, particularly NdFeB system, NdDyFeB, NdFeCoB system, SmCo system, SmCoFe are, SmFeN is, the residual magnetic flux density height of SmCoZrN system, so, can make the induced voltage height.After the powder of these hard magnetic materials being formed the adjustment of adjustment and granularity, make magnetic flux on specific direction, be orientated ground as magnet in above-mentioned powder by magnetic field and use.In addition, soft magnetic material 3 is configured to the peripheral part of annular magnet by the number identical with number of poles.For soft magnetic material 3, the Fe alloy is because of the magnetic permeability height, and becomes optimal selection, and Fe-Si, Fe-Al, Fe-B, Fe-C etc. are good.
The following describes from being orientated sintering circuit.At first, use the forming metal mould of square long size at 1～10tcm
2Shaping soft magnetic material 3 under the following pressure.Magnetic field in the shaping for no magnetic field or on the direction that becomes radially externally-applied magnetic field.In above-mentioned Fe alloyed powder, add about 1% stearic acid, form after fully mixing as lubriation material.With the formed body of the powder of soft magnetic material along the outer circumferential side that circumferentially is configured to the orientation metal mould by the cardinal principle equal intervals.The section configuration that relative its length direction of soft magnetic material 3 is vertical also can be simple shapes such as circle, triangle, ellipse in addition.
Then, the formed body of soft magnetic material 3 is configured to the outer circumferential side in the metal pattern of double-layered cylinder shape, the powder of above-mentioned hard magnetic material 4 is injected in this metal pattern.Outer circumferential side in metal pattern can insert the recess that the length shape identical with it with width is set partially with the formed body of soft magnetic material 3, is embedded into this place, makes when the powder injection of hard magnetic material 4 and can not move during press molding.In addition, the length of metal pattern is longer than the formed body of soft magnetic material 3, becomes the length identical with the formed body of soft magnetic material 3 behind the press molding, and bigger, its pressure side is set as flat.Make the orientation of the powder of hard magnetic material 4 carry out press molding towards radially by magnetic field from coil or magnet.Forming pressure is 1～10t/cm
2As use the powder of NdFeCoB system of the particle diameter of 1～3 μ m, then by adding the magnetic field of 80000e, can be in footpath shown in the direction of orientation 2 of the direction of easy axis of the hard magnetic material 4 that is shown in Fig. 5 orientation upwards.The degree of orientation of the powder of hard magnetic material 4 is more than 80% at this moment.Can obtain the correct configuration of the formed body of soft magnetic material 3 by this metal pattern.
(vacuum degree 1 * 10 in a vacuum
-2Pa) make the powder sintering of such press molding, under 400～500 ℃, prepare sintering earlier.Lubricant evaporation this moment.Sintering temperature generates the Nd amount and compares Nd in (5 hours) below 1200 ℃ more than 800 ℃
2(Fe, Co)
14B (principal phase) and Nd
2(Fe, Co)
14The phase that B is big (rich Nd phase) is NdFe
4B
4This richness Nd mutually also sintering play the effect of binding agent, the interface of soft magnetic material 3 and hard magnetic material is sintering also.In addition, obtain the also few annular magnet of form variations of each utmost point behind the sintering during sintering by the correct configuration of the formed body of soft magnetic material 3.
Behind the sintering, heat-treat in the temperature of (5 hours) below 1000 ℃ more than 600 ℃ once more in order to increase coercive force.The particle diameter of the principal phase after the heat treatment is 2～15 μ m.To Zhou Jinhang processing inside and outside the periphery, form the such annular magnet of Fig. 1 after the heat treatment.This annular magnet is 8 utmost points, disposes soft magnetic material 3 at outer circumferential side by the quantity identical with number of poles.The position of 1 soft magnetic material in week upwards be 1 utmost point angle 5～10%.Make at the thickness of radially pressing 3～10%.
(embodiment 2)
Fig. 2 is the sectional drawing that the annular magnet of soft magnetic material 3 circumferentially periodically is set on the extreme portion outer circumferential side edge of utmost point anisotropy annular magnet of the present invention.In Fig. 2, hard magnetic material 1 is an annular, and the easy axis 2 of hard magnetic material 1 is along circumferentially periodically changing.Dispose soft magnetic material 3 at outer circumferential side by the periodicity outwardly that same side face protrudes soft magnetic material 3, integral body is the magnet of one.The material of hard magnetic material 1 is used and embodiment 1 identical materials.
Soft magnetic material 3 uses iron powder.Electrolytic iron powder at particle diameter 5～20 μ m adds about 1% zinc stearate as lubriation material, is inserted into metal pattern after the mixing, and press molding forms tetragonal long size shape similarly to Example 1.Hard magnetic material 1 uses the magnetic of NdFeB system.NdFeB is that the particle diameter of magnetic is 3～15 μ m.In order to improve energy product, use the monocrystalline powder of average grain diameter 3～5 μ m.This magnetic is inserted in the metal pattern of the formed body of outer circumferential side configuration soft magnetic material 2.After this, in the magnetic field of 80000e with 1t/cm
2Pressure forming.By the coil of the outer circumferential side that is configured to metal pattern or interior all sides direction of easy axis 2 controlling magnetic field directions, externally-applied magnetic field when being shaped along the hard magnetic material of Fig. 2.The magnetic direction that the edge is circumferentially continuous and the periodic variation coil produces in ring.
In Fig. 2, add coil corresponding to number of poles in outer circumferential side or 8 pairs of magnetic fields of interior all side configurations of magnetic insertion section, make magnetic direction upwards being roughly design lines circle position, sinusoidal rolling land week, be applicable to metal pattern.The electric current that flows in coil is 1 * 10
6A/cm
2, applying pulse electric current when being shaped.After adding the magnetic field that makes hard magnetic material orientation and being shaped, Nd
2Fe
14The c axle of the tetragonal of the direction of easy axis of B is arranged along the direction of orientation 2 of the direction of easy axis of the hard magnetic material of Fig. 4.Similarly to Example 1 behind the sintering or behind the sintering, heat treatment, Nd
2Fe
14The c axle of B is also arranged along the direction of orientation 2 of hard magnetic material shown in Figure 4.After sintering, the heat treatment, be annular, use the magnetization yoke to make Nd by the processing of diamond or emery wheel or being processed to form of line cutting
2Fe
14B (more than the 15kOe of magnetic field) becomes the annular magnet of Fig. 2, the magnetic permeability that the annular magnet periodic variation is circumferential.
Soft magnetic material 3 be shaped as 8 polar ring shape magnet, be the circumferential width below 1/2 of the angle of 1 utmost point, be below 1/2 of radial thickness radially in the position of outer circumferential side, preferably identical with embodiment 1.When the volume fraction of radially soft magnetic material 3 1/2 when above, the wave distortion of surface magnetic flux density is more than 5%, the peak value of surface magnetic flux density also descends.In addition, when circumferential soft magnetic material 3 1/2 when above, the wave distortion of surface magnetic flux density obviously increases.
(embodiment 3)
Present embodiment uses SmCo system to replace Nd as the hard magnetic material 1 of embodiment 2
2Fe
14B, when being for SmCo, under the temperature lower than sintering temperature by the solution treatment homogenizing.With Sm
2Co
17Powder be inserted in the metal pattern that disposes the soft magnetic material formed body similarly to Example 2, adding press molding under the state of alignment magnetic field.Soft magnetic material 3 uses electrolysis Fe powder.The forming pressure of electrolysis Fe powder is about 5t/cm
2Sm
2Co
17Magnetic field when powder is shaped is more than the 70000e, makes c axle orientation along magnetic direction.Pressure during shaping is 1～10t/cm
2In vacuum furnace, similarly to Example 1 formed body is prepared sintering, in addition, behind 1000～1200 ℃ of following sintering, under 700～900 ℃, heat-treat.Atmosphere during sintering is hydrogen, inert gas or vacuum.Part by the Co in will forming changes over Cu, and can obtain energy product (Bhmax) by the coercive force that surpasses 10kOe is 90kJ/m
3Annular magnet.
Sm behind the sintering
2Co
17Orientation as shown in Figure 2 along circumferentially periodically changing continuously.Make direction of easy axis along such orientation be designed for the coil of the orientation yoke that orientation is shaped or the position of magnet.Coil or magnet are configured to outer circumferential side or interior all sides of the magnetic insertion section of annular corresponding to number of poles.The 8 polar ring shape magnet that are shaped as Fig. 2 of retentive material 3 are the circumferential width below 1/2 of the angle of 1 utmost point, are below 1/2 of radial thickness in the position of outer circumferential side radially, and are preferably identical with embodiment 1.When the volume fraction of radially soft magnetic material 1/2 when above, the wave distortion of surface magnetic flux density is more than 5%, the peak value of surface magnetic flux density also descends.
In addition, when circumferential soft magnetic material 1/2 when above, the wave distortion of surface magnetic flux density obviously increases.After the processing, make Sm
2Co
17Magnetization is also measured the magnetic permeability of the annular magnet of Fig. 2, and the result shows, magnetic permeability at the outer circumferential side of soft magnetic material 3 up to more than 5%.
In addition, when circumferentially changing continuously, as be the material of same shape, same magnetic on the orientation edge of the such direction of orientation 2 of Fig. 2, then surface magnetic flux density is than Fig. 1 height.As at the easy magnetizing axis that makes progress in week to the annular magnet that changes, then the position of soft magnetic material 3 wave distortion of surface magnetic flux density when the absolute value of surface magnetic flux density is peaked angle and leaves diminishes.Therefore, form the configuration of soft magnetic material 3 as shown in Figure 2.In Fig. 2, the position configuration of soft magnetic material is the angle of maximum and the centre position of angle to the absolute value of surface magnetic flux density.Absolute value at surface magnetic flux density is that direction of easy axis is roughly radially under the angle of maximum, and the orientation of hard magnetic material is as shown in Figure 2 towards approaching circumferential direction near soft magnetic material 3.The surface magnetic flux density height of such annular magnet can improve induced voltage, and the magnetic permeability of the part of soft magnetic material 3 is bigger than 1.1, so magnetic resistance is circumferentially periodically changing.
The occasion that is used for embodiment 1 in the SmCo system with the hard magnetic material 1 of present embodiment also can obtain same effect.
(embodiment 4)
Fig. 3 is the sectional drawing that the annular magnet of soft magnetism portion circumferentially periodically is set on interior all sides edge of utmost point anisotropy annular magnet of the present invention.In Fig. 3, hard magnetic material 1 is an annular, and the direction of orientation 2 of the easy axis of hard magnetic material 1 is along circumferentially periodically changing.Make the surface of soft magnetic material 3 periodically dispose soft magnetic material 3 projectedly in interior all sides, integral body is the magnet of one.
Soft magnetic material 3 uses iron powder.Electrolytic iron powder at particle diameter 5～20 μ m adds about 1% zinc stearate as lubriation material, is inserted into metal pattern after the mixing.Hard magnetic material 1 uses the magnetic of NdFeB system.NdFeB is that magnetic is selected Nd corresponding to the magnetic characteristic that requires, manufacturing cost, environment for use
2Fe
14B, (M, Dy)
2Fe
14B, (Nd, Dy)
15Fe
77B
7Al
1, (Nd, Dy)
2(Fe, Co)
14B, but, also can be in above-mentioned NdFeB system and the SmCo system any for the magnetic permeability that configuration soft magnetic material 3 is obtained changed in the circumferential last cycle.Metal pattern forms periphery and the interior all identical construction that makes embodiment 1.Can obtain the few annular magnet of form variations thus.
The NdFeB that uses is that the particle diameter of magnetic is 3～15 μ m.In order to improve energy product, use the monocrystalline powder of average grain diameter 35 μ m.This magnetic is inserted in the metal pattern of the formed body that disposes soft magnetic material.After this, in the magnetic field of 80000e with 1t/cm
2Pressure forming.By the coil of the outer circumferential side that is configured to metal pattern or interior all sides direction of easy axis 2 controlling magnetic field directions, externally-applied magnetic field when being shaped along the hard magnetic material of Fig. 3.The magnetic direction that the edge is circumferentially continuous and the periodic variation coil produces in ring.
In Fig. 3, use 8 pairs of magnetic fields to add coil, make magnetic direction upwards being roughly design lines circle position, sinusoidal rolling land week, be applicable to metal pattern.The electric current that flows in coil is 1 * 10
6A/cm
2, applying pulse electric current when being shaped.After adding the magnetic field that makes hard magnetic material orientation and being shaped, Nd
2Fe
14The c axle of the tetragonal of the direction of easy axis of B is arranged generally along the direction of easy axis 2 of the hard magnetic material of Fig. 3.Similarly to Example 1 behind the sintering or behind the sintering, heat treatment, Nd
2Fe
14The c axle of B is also arranged along the direction of easy axis 2 of hard magnetic material shown in Figure 3.After sintering, the heat treatment, be annular, use the magnetization yoke to make Nd by the processing of diamond or emery wheel or being processed to form of line cutting
2Fe
14B (more than the 15kOe of magnetic field) becomes the annular magnet of Fig. 3.
The 8 polar ring shape magnet that are shaped as Fig. 3 of soft magnetic material 3 are the circumferential width below 1/2 of the angle of 1 utmost point, are below 1/2 of radial thickness in the position of outer circumferential side radially.When the volume fraction of radially soft magnetic material 3 1/2 when above, the wave distortion of surface magnetic flux density is more than 5%.Preferably identical with embodiment 1.
As not disposing soft magnetic material 3, only make annular magnet by hard magnetic material 1, then become the such state of Fig. 4.The orientation of the hard magnetic material 1 of Fig. 4 is along circumferentially continuously and periodically repeatedly, the direction of orientation 2 of the direction of easy axis of hard magnetic material repeatedly 8 times as shown in Figure 4.The magnetic permeability of the outer circumferential side of the annular magnet that Fig. 4 is such did not upwards change substantially in week.For this reason, be difficult to make full use of reluctance torque.
Carry out annular processing for the sintered body of the formation that obtains Fig. 3, when making Nd
2Fe
14B magnetization and when measuring the magnetic permeability of annular magnet, magnetic permeability is more than 2% at the outer circumferential side of soft magnetic material 3, and is higher.In addition, the hard magnetic material 2 that Fig. 3 is such be oriented in week when upwards changing continuously, as be same shape, same magnetic material, then surface magnetic flux density is than Fig. 1 height.As be easy magnetizing axis to the annular magnet that upwards changes in week, then the position of soft magnetic material 3 wave distortion of surface magnetic flux density when the absolute value of surface magnetic flux density is peaked angle and leaves diminishes.
Therefore, as shown in Figure 2 soft magnetic material 3 is configured to the face side of hard magnetic material 1.In Fig. 3, the absolute value that interior all side positions of soft magnetic material are configured to surface magnetic flux density is the maximum angle and the centre position of angle.Absolute value at surface magnetic flux density is that direction of easy axis is roughly radially under the angle of maximum, and the orientation of hard magnetic material 1 is as shown in Figure 3 towards approaching circumferential direction near soft magnetic material 3.The occasion that soft magnetic material is configured to interior all sides is compared with the occasion that soft magnetic material 3 is configured to Fig. 2 outer circumferential side, and the absolute value of surface magnetic flux density increases.This be since when soft magnetic material is near surface magnetic flux or magnetic direction the direction of magnet effect is exerted an influence, the configuration of Fig. 3 of interior all sides is less to the variable effect of the value of surface magnetic flux density.The surface magnetic flux density height of the annular magnet that Fig. 3 is such can improve induced voltage, and the magnetic permeability of the part of soft magnetic material 3 is bigger than 1.1, so magnetic resistance is circumferentially periodically changing.
(embodiment 5)
Fig. 5 is the sectional drawing of the annular magnet that soft magnetism portion radially is set of the extreme portion at utmost point anisotropy annular magnet of the present invention.In Fig. 5, hard magnetic material 1 is an annular, and the direction of orientation 2 of the easy axis of hard magnetic material 1 is along circumferentially periodically changing.Periodically dispose soft magnetic material 3 in interior all sides of hard magnetic material 1 and each surperficial continuous flat soft magnetic material that protrudes 3 of outer circumferential side along circumferential, integral body is the magnet of one.
Soft magnetic material 3 uses iron powder.Electrolytic iron powder at particle diameter 5～20 μ m adds about 1% zinc stearate as lubriation material, is inserted into metal pattern after the mixing, and press molding forms tabular similarly to Example 1.Hard magnetic material 1 uses the magnetic of the NdFeB system that uses in the embodiments of figure 3.This hard magnetic is inserted in the metal pattern of the formed body that has disposed soft magnetic material 3.After this, in the magnetic field of 80000e with 1t/cm
2Pressure forming.By the coil of the outer circumferential side that is configured to metal pattern or interior all sides direction of orientation 2 controlling magnetic field directions, externally-applied magnetic field when being shaped along the direction of easy axis of the hard magnetic material 1 of Fig. 5.The magnetic direction that the edge is circumferentially continuous and the periodic variation coil produces in ring.In this metal pattern, in interior periphery the groove of recess is set similarly to Example 1, the formed body of soft magnetic material 3 is guaranteed correct position when press molding.
Use 8 pairs of magnetic fields to add coil in the orientation metal mould that uses for the magnet of construction drawing 5, magnetic direction upwards is being roughly design lines circle position, sinusoidal rolling land week and is being used.The electric current that flows in coil is 1 * 10
6A/cm
2, applying pulse electric current when being shaped.After adding the magnetic field that makes hard magnetic material 1 orientation and being shaped, Nd
2Fe
14The c axle of the tetragonal of the direction of easy axis of B is arranged along the direction of orientation 2 of the direction of easy axis of the hard magnetic material 1 of Fig. 5.Behind the sintering or behind the sintering, heat treatment, Nd
2Fe
14The c axle of B is also arranged along the direction of orientation 2 of the direction of easy axis of hard magnetic material 1 shown in Figure 5.
After carrying out sintering, heat treatment similarly to Example 1, be annular, use the magnetization yoke to make Nd by the processing or being processed to form of line cutting of diamond or emery wheel
2Fe
14B (more than the 15kOe of magnetic field) becomes the annular magnet of Fig. 5.
The shape of soft magnetic material 3 is the circumferential width below 1/2 of the angle of 1 utmost point in the occasion of the 8 polar ring shape magnet of Fig. 5, preferably relatively circumferentially to per 1 very 5～10%.After the processing, make Nd
2Fe
14B magnetization is also measured the magnetic permeability of the annular magnet of Fig. 5, and the result shows, magnetic permeability at the outer circumferential side of soft magnetic material 3 up to more than 10%.In addition, for the annular magnet of Fig. 5, can make Nd
2Fe
14The degree of orientation of the magnetic orientation of B can improve induced voltage more than 90%.This is can be approaching sinusoidal wave owing to being compared with other example in the position of hard magnetic material by the direction of the magnetic circuit that is orientated the soft magnetic material making in the forming process, and can obtain high magnetic field.
(embodiment 6)
Above-mentioned Fig. 2, Fig. 3, annular magnet shown in Figure 5 also can be made of soft magnetic material 3, and this soft magnetic material 3 is for having the part than little coercive force of coercive force shown in the hard magnetic material 1 that is formed by the magnetic material near utmost point anisotropic magnet or the magnetic permeability bigger than hard magnetic material 1.The direction of orientation 2 of the direction of easy axis of the magnetic material of hard magnetic material 1 is shown by dashed lines.In this occasion is 8 utmost points, but as long as 2 extremely more than then number of poles be not particularly limited.Hard magnetic material 1 be in the magnetic characteristic residual magnetic flux density (Br) more than the 0.6T, the magnetic material of coercive force (iHc) more than 5kOe, use the rare earth element (occasion of adding other rare earth elements such as Dy at Nd is also arranged) of NdFeB system and Fe (occasion of adding Co is also arranged), B (occasion of adding the semimetallic elements beyond the B is also arranged) or SmCo to be.
In the production process of sintered magnet, use by pulverize and classification to the particle size distribution of magnetic raw meal carry out after reunification by the orientation that is referred to as magnetic field orientating be shaped unify powder towards operation.At this moment, insufficient as the direction and the magnetic field intensity of alignment magnetic field, magnetic towards can not be fully unified then.The orientation of the magnetic of looping magnet is as making extremely central authorities or extremely the orientation difference of portion according to number of poles, the angle interdependence that then can be used as X-ray diffraction intensity detects.Here, extreme portion refers to the position of the wheel magnetic material 3 of Fig. 5, and utmost point center is turned back to the middle position of the position of next soft magnetic material from the position of the soft magnetic material 3 of Fig. 5.
Fig. 3 is shown in dotted line orientation (direction identical with direction of easy axis).The position of above-mentioned extreme portion becomes and the circumferential position of equidirectional (with radially vertical direction) for this dotted line.That is, at the relative radially or circumferentially right angle each other mutually of extreme portion with the direction of orientation of utmost point center.The dotted line of Fig. 3 only is schematically to illustrate, and for the direction of the magnetic that constitutes magnet, in fact is difficult to make 100% magnetic towards such dotted line.The size of magnetic is that its particle diameter distributes in certain limit below several μ m, and shape is also incomplete same, also is offset adding under the state of alignment magnetic field sometimes, is difficult to unify the orientation towards magnetic direction fully under the state that magnetic is in contact with one another.The direction of orientation 2 of showing the direction of easy axis of hard magnetic material shown by dashed lines in Fig. 2, Fig. 3, Fig. 5 is at the less soft magnetic material 3 of extreme portion's configuration coercive force.It is integrally formed with hard magnetic material 1 that configuration is formed at the less part of the coercive force of position of soft magnetic material 3.Its gimmick has before sintering circuit the method etc. that formed body with soft magnetic material 3 is configured to the method for the position of soft magnetic material 3, changes the magnetic characteristic of the part that changes soft magnetic material 3 after the method, sintering of conditions such as sintering temperature of part of soft magnetic material 3 in sintering circuit.
For the part at soft magnetic material 3 before sintering disposes soft magnetic material, shaping is being divided into the method that 2 grades of alignment magnetic fields that carry out sintering after being made into body or reduce the part of soft magnetic material 3 change near the magnetic characteristic it thereby have, thereby and after making utmost point anisotropic magnet be orientated shaping, only near soft magnetic material 3, is adding the method that the highfield changes magnetic characteristic.
In sintering circuit, the gimmick of the conditions such as sintering temperature of the part of change soft magnetic material 3 can only make the part of soft magnetic material 3 more high or low than common sintering temperature, thereby reduces coercive force.Behind sintering, in the gimmick of the magnetic characteristic of the part of change soft magnetic material 3, can reduce coercive force by after sintering, processing, the part of soft magnetic material 3 being carried out overheated chilling.Even magnet is not extremely anisotropic orientation, and is such as shown in the figure in the occasion of the radial oriented annular magnet with Fig. 1 yet, by the circumferential part of arranging soft magnetic material 3 periodically in edge, thereby it is poor to form magnetic resistance.
At the material of the part that becomes soft magnetic material 3 is the occasion of NdFeB system, the material that can use the size ratio other parts of powder to increase 1 figure place to reduce coercive force abovely, in the composition of NdFeB system, form near the material of the quasi-steady structure of noncrystalline or metal glass, in the powder that NdFeB is different strong magnetic material (α-Fe, the Fe of mixing magnetic characteristic
3B, Fe
4N, Fe
2O
3Deng) material, have the magnetic material of soft magnetic characteristics such as Fe-Si alloy.
Fig. 6 illustrates the NdFeB based magnet at the line chart of waveform of surface magnetic flux density that uses the occasion of Fe-3%Si powder one sintering near extremely anisotropic ring as shown in Figure 3 at the soft magnetic material 3 of interior all sides.The powder that uses is Nd
2Fe
14The anisotropic magnet powder of B, its coercive force (iHe) are that 15～25kOe, Br are the powder of 1.1～1.3T.The position (position of the soft magnetic material 3 of Fig. 3) that the Fe-3%Si powder of soft magnetism is shown is foreclosed, and is that magnetic is orientated shaping at NdFeB in advance only, after this, and with the powder press molding of above-mentioned soft magnetic material position to the soft magnetic material 3 of Fig. 3.The radially volume fraction of the soft magnetic material of this occasion is 20%, and circumferential (position of the soft magnetic material 3 of Fig. 3) width is about 5 degree.This angle is preferably below 1/2 of angle (occasion of 8 utmost points is 45 degree) of 1 utmost point.Being orientated needed magnetic field is more than the 50000e.After this, above-mentioned formed body is put into heat-agglomerating in the vacuum furnace.Sintering temperature is 800～1200 ℃.Process behind the sintering, form surface protection film as required.Fig. 3 illustrates the occasion of 8 utmost points, but also can make in 2 the occasions of any number of poles more than extremely.
In Fig. 6, the longitudinal axis is a relative value, and transverse axis is an angle.The magnet external diameter is 30mm, and internal diameter is 20mm, highly is 20mm.Locating is the height 10mm of outer circumferential side, uses Hall unit mensuration surface magnetic flux density radially.The waveform of surface magnetic flux density is near sinusoidal wave, and this wave distortion is about 4%.In addition, the peak value of surface magnetic flux density is equal to or is higher than the radial ringed magnet by identical shaped making.
(embodiment 7)
Fig. 7 illustrates discussion increases the wave distortion of the volume fraction of soft magnetic material of occasion of volume fraction of soft magnetic material radially and surface magnetic flux density in embodiment 6 the line chart of relation.As shown in Figure 7, when the volume fraction of soft magnetic material increased, the wave distortion of surface magnetic flux density increased.In addition, as shown in Figure 8, magnetic permeability particularly is increased to 20% sharp also along with the increase of the volume fraction of soft magnetic material and increase.
As shown in Figure 7, the wave distortion increase of surface magnetic flux density can be thought because the existence of the powder of soft magnetic material makes the magnetic characteristic deterioration that causes as the diffusion between the powder of the orientation variation of the powder of the NdFeB of the powder of hard magnetic material and soft magnetic material and hard magnetic material etc.In order to ensure reluctance torque, inhibition wave distortion, the radially volume fraction that preferably makes soft magnetic material is 5～50%.In this scope, the magnetic permeability at the utmost point center of annular magnet is 1.0～1.05.The powder that makes soft magnetic material among Fig. 5 is 100% diametrically, but Fig. 7 shows, when the part of soft magnetic material 3 is the mixture of soft magnetism and hard magnetic wave distortion is reduced effectively.
(embodiment 8)
Fig. 9 and Figure 10 are for using the perspective view of the rotor of the annular magnet of making in embodiment 1～7.Use the bonding annular magnet 11 of bonding agent of organic system in the axial central authorities of gyroaxis 12.Be outside its mutual difference soft magnetic material to be set or to be arranged on outer circumferential side according to the interior all sides of being configured in of motor.In addition, also be used for the occasion of external rotor in the orientation of utmost point anisotropy annular magnet, at interior all side magnetic flux grows.Also can as shown in Figure 10 soft magnetic material 13 be tilted, reduce cogging torque.Gyroaxis 12 forms and the corresponding diameter of the needed torque of motor in the part (metastomium) of bonding annular magnet 11, and the gyroaxis 12 of both sides becomes maximum gauge relatively.Pars intermedia has the diameter ground that can guarantee as the intensity of gyroaxis 12 and forms tiny diameter with reducing weight as much as possible.
Figure 11 is the sectional drawing of the motor of the rotor of use Fig. 9 and Figure 10.This motor can utilize reluctance torque, and this reluctance torque has been utilized the poor of magnetic resistance, so, can under the slow-speed of revolution, guarantee high torque.Particularly this motor is requiring on the hybrid car with internal combustion engine and motor of low speed, high torque (HT) effectively.
According to the present invention, the surface magnetic flux density of annular magnet or induction voltage waveform are near sinusoidal wave, in addition, the orientation at the utmost point center by improving annular magnet, and, by along the powder that circumferentially forms soft magnetic material periodically, can be along circumferential generation magnetic permeability, the rotor that can provide the wave distortion of surface magnetic flux density little, cogging torque is little, in addition, applicable to the motor that can utilize the reluctance torque under the slow-speed of revolution.Particularly can make high efficiency motor, applicable to the conveying of industry usefulness, automobile-use, semiconductor device etc., positioning motor etc.
Claims (17)
1. annular magnet is characterized in that: direction of easy axis along in the circumferential or radially periodically variable annular hard magnetic material along circumferential integrally formed at regular intervals a plurality of soft magnetic materials.
2. an annular magnet is characterized in that: circumferentially imbed a plurality of soft magnetic materials at regular intervals in direction of easy axis along the outer circumferential side of circumferential or radially periodically variable annular hard magnetic material or at least one side edge of interior all sides, form.
3. an annular magnet is characterized in that:, form along circumferentially circumferentially imbedding a plurality of soft magnetic materials at regular intervals with the outer circumferential side of the periodically variable annular hard magnetic material of sinusoidal wave shape or at least one side edge of interior all sides in direction of easy axis.
4. annular magnet is characterized in that: direction of easy axis along circumferentially with sinusoidal wave shape in the periodically variable annular hard magnetic material along circumferentially imbed at regular intervals a plurality of from interior all sides to the continuous soft magnetic material of outer circumferential side, form.
5. annular magnet according to claim 1 is characterized in that: by sintering integrated above-mentioned hard magnetic material and the soft magnetic material of forming.
6. annular magnet according to claim 1 is characterized in that: above-mentioned hard magnetic material and soft magnetic material carry out above-mentioned sintering behind the press molding in magnetic field.
7. annular magnet according to claim 1 is characterized in that: above-mentioned soft magnetic material is formed at the direction of easy axis that makes progress in week of above-mentioned hard magnetic material towards above-mentioned circumferential position.
8. annular magnet manufacture method is characterized in that: be included in the formation operation that circumferentially disposes the complex of a plurality of soft magnetic materials at regular intervals in the hard magnetic material powder of loop configurations, above-mentioned complex be orientated in magnetic field and under this state formation press molding body the press molding operation and make above-mentioned press molding body carry out the sintering circuit of sintering.
9. annular magnet manufacture method is characterized in that: be included in at least one side of the outer circumferential side in the hard magnetic material powder of loop configurations or interior all sides along the formation operation that circumferentially disposes the complex of a plurality of soft magnetic materials at regular intervals, above-mentioned complex be orientated in magnetic field and under this state formation press molding body the press molding operation and make above-mentioned press molding body carry out the sintering circuit of sintering.
10. annular magnet manufacture method is characterized in that: be included in the part in the hard magnetic material powder of loop configurations along the formation operation that circumferentially disposes complex at regular intervals from interior all sides to the continuous a plurality of soft magnetic materials of outer circumferential side, above-mentioned complex be orientated magnetic field and under this state formation press molding body the press molding operation and make above-mentioned press molding body carry out the sintering circuit of sintering.
11. annular magnet manufacture method according to claim 8 is characterized in that: the direction of easy axis of the hard magnetic material of above-mentioned annular circumferentially or is radially being adjusted to cyclic variation above-mentioned magnetic direction.
12. annular magnet manufacture method according to claim 8 is characterized in that: above-mentioned soft magnetic material obtains by in the magnetic field that becomes direction radially or in no magnetic field the soft magnetic material powder being carried out press molding.
13. annular magnet manufacture method according to claim 8 is characterized in that: above-mentioned soft magnetic material is configured to the direction of easy axis of above-mentioned hard magnetic material towards above-mentioned circumferential position.
14. a rotor is arranged at a periphery with annular magnet, it is characterized in that: above-mentioned annular magnet is made of the described annular magnet of claim 1.
15. a rotor is arranged at a periphery with annular magnet, it is characterized in that: above-mentioned annular magnet is made of the annular magnet that forms by the described annular magnet manufacture method of claim 8.
16. a rotating machinery has stator and rotating rotor in this stator; It is characterized in that: above-mentioned rotor is made of the described rotor of claim 14.
17. rotating machinery according to claim 16 is characterized in that: relative nominal torque, cogging torque is below 5%.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002280596A JP2004120892A (en) | 2002-09-26 | 2002-09-26 | Ring magnet, its manufacturing method, and rotor and motor using this ring magnet |
| JP280596/2002 | 2002-09-26 |
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| CN1485862A true CN1485862A (en) | 2004-03-31 |
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| CNA03107412XA Pending CN1485862A (en) | 2002-09-26 | 2003-03-20 | Annular magnet and method for producing the same, and rotor and motor using the same |
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| CN (1) | CN1485862A (en) |
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