JP2019146463A - Rotor of rotary electric machine, rotary electric machine, and method for manufacturing rotor of rotary electric machine - Google Patents

Abstract

To provide a rotor of a rotary electric machine capable of improving torque density, and the rotary electric machine.SOLUTION: A first rotary electric machine 11 comprises: a rotor core 25 having a plurality of magnet slots 29 housing a permanent magnet 31 extended in a rotation axis direction and provided in a circumferential direction; and a pair of end surface plates 27 provided in end portions of the rotor core 25 in the rotation axis direction, respectively. In the first rotary electric machine 11, positioning of the permanent magnet 31 to the magnet slot 29 of the rotor core 25 is performed by positioning one end portion of the permanent magnet 31 in the end surface plate 27 through an intermediate member 35 by fitting the intermediate member 35 connected to the one end portion of the permanent magnet 31 in a hole 37 provided in the end surface plate 27.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a rotor of a rotating electrical machine capable of improving torque density, a rotating electrical machine, and a rotor manufacturing method of the rotating electrical machine.

  In recent years, as an approach for realizing a low-carbon society, vehicles equipped with rotating electrical machines have become widespread in addition to or instead of the internal combustion engine that is a driving source of the vehicle. Such vehicles are hybrid vehicles (Hybrid Electric Vehicles) and electric vehicles (Electric Vehicles).

  The rotating electrical machine includes, for example, an annular stator and a cylindrical rotor. The stator is configured by providing a stator coil in each of a plurality of slots provided in the stator core. The rotor is rotatably provided with a slight gap with respect to the inner peripheral surface of the stator. The rotor is provided with a rotation shaft. A rotor core provided in the rotor is provided with a plurality of magnet insertion holes at equal intervals in the circumferential direction.

  In each of the plurality of magnet insertion holes, for example, as shown in Patent Document 1, a rectangular bar-shaped permanent magnet is embedded. The installation position of the permanent magnet in the direction orthogonal to the longitudinal direction is regulated by the positioning portion provided in the magnet insertion hole.

  In a rotating electric machine, various operations including copper loss (loss due to the electrical resistance of the stator coil), iron loss (loss due to magnetic properties of the magnetic material such as the stator core), and mechanical loss (loss due to mechanical factors such as friction) during operation. Loss occurs and heat is generated. When the rotating electrical machine generates heat, stress acts on the corners of the permanent magnet based on the difference in linear expansion coefficient between the rotor core and the permanent magnet. Also, when the rotating electrical machine rotates at a high speed, stress acts on the corners of the permanent magnet due to the centrifugal force acting on the permanent magnet.

  In order to relieve the stress acting on the corners of the permanent magnet, an R-shaped relief portion (described in paragraph No. 0039 of Patent Document 1) is provided at the magnet insertion hole portion (positioning portion) corresponding to the corner of the permanent magnet. "Hole spaces 257b1 and 257b2" and Fig. 5 of Patent Document 1) are provided.

  According to the rotor structure of the rotating electrical machine according to Patent Document 1 (the portion of the magnet insertion hole corresponding to the corner portion of the permanent magnet is provided with an R-shaped relief portion), the stress acting on the corner portion of the permanent magnet is relieved. Can do.

WO2015 / 076045

  However, when the rotor structure (R-shaped relief portion) of the rotating electrical machine according to Patent Document 1 is employed, the following problems occur. That is, in the vicinity of the corner portion of the permanent magnet, an air gap is generated between the permanent magnet and the rotor core due to the R-shaped relief portion. When such a gap is interposed between the permanent magnet and the rotor core, the magnetic resistance increases due to the influence of the gap, which may cause a decrease in torque density.

  This invention is made | formed in view of the said situation, and it aims at providing the rotor and rotary electric machine of a rotary electric machine which can improve a torque density.

  Another object of the present invention is to provide a rotor manufacturing method for a rotating electrical machine that can improve torque density.

  In order to achieve the above object, the invention according to claim 1 is directed to a rotor core having a plurality of magnet slots provided along a circumferential direction for accommodating a permanent magnet extending in a rotation axis direction, and a rotation axis direction end of the rotor core. A rotor of a rotating electrical machine provided with a pair of end face plates provided in each of the portions, wherein a portion of the magnet slot facing the inner diameter side wall portion of the permanent magnet is continuous along the shape of the inner diameter side wall portion. A wall portion is formed, and at least one of the end portions in the rotation axis direction of the permanent magnet is joined to an intermediate member exhibiting a low relative permeability relative to the relative permeability of the rotor core, of the pair of end face plates The end plate on the side facing at least one of the end portions in the rotation axis direction of the permanent magnet is provided with a hole portion into which the intermediate member is fitted, and the inner wall portion of the permanent magnet is formed in the continuous wall portion of the magnet slot. Is In this state, the permanent magnet is accommodated in the magnet slot, and the intermediate member is fitted into the hole, so that the one end portion in the rotation axis direction of the permanent magnet is in contact with the intermediate member via the intermediate member. The most important feature is that it is positioned on the end face plate facing one side.

  In the invention which concerns on Claim 1, a permanent magnet is accommodated in a magnet slot in the state which the inner-diameter side wall part of the permanent magnet contact | abutted to the continuous wall part of the magnet slot. There is substantially no air gap between the permanent magnet and the rotor core (magnet slot). The positioning of the permanent magnet with respect to the rotor core is achieved by fitting one end of the permanent magnet through the intermediate member by fitting the intermediate member provided at one end of the permanent magnet into the hole provided in the end face plate. This is accomplished by positioning on the end plate.

  ADVANTAGE OF THE INVENTION According to this invention, the rotor of the rotary electric machine which can improve a torque density can be obtained.

It is a front view showing the whole 1st rotation electrical machinery composition concerning a 1st embodiment of the present invention. It is a figure which expands and represents the periphery of the permanent magnet provided in the magnet slot of the rotor core among the 1st rotary electric machines shown to FIG. 1A. It is a longitudinal cross-sectional view showing a part of 1st rotary electric machine. It is a perspective view showing the state which matched the relative positional relationship of the hole provided in the end surface board with which the rotor of a 1st rotary electric machine was equipped, and the intermediate member. FIG. 3B is a perspective view conceptually expanding and representing a relative positional relationship between a hole provided in the end face plate illustrated in FIG. 3A, an intermediate member, and a permanent magnet to which the intermediate member is joined. FIG. 4 is a process diagram illustrating a rotor manufacturing method of first rotating electrical machine 11. It is a front view showing the whole structure of the 2nd rotary electric machine which concerns on 2nd Embodiment of this invention. It is a figure which expands and represents the periphery of the permanent magnet provided in the magnet slot of the rotor core among the 2nd rotary electric machines shown to FIG. 5A. It is a perspective view showing the state which matched the relative positional relationship of the hole provided in the end surface board with which the rotor of a 2nd rotary electric machine was equipped, and the intermediate member.

  Hereinafter, a rotor of a rotating electrical machine, a rotating electrical machine, and a rotor manufacturing method of the rotating electrical machine according to an embodiment of the present invention will be described in detail with reference to appropriate drawings.

In addition, in drawing shown below, the same referential mark shall be attached | subjected between the same members or corresponding members. In addition, the size and shape of the member may be schematically represented by being deformed or exaggerated for convenience of explanation.
[Configuration of the first rotating electrical machine 11 according to the first embodiment of the present invention]
First, the 1st rotary electric machine 11 which concerns on 1st Embodiment of this invention is demonstrated in detail with reference to FIG. 1A, FIG. 1B, and FIG.

  FIG. 1A is a front view illustrating the overall configuration of the first rotating electrical machine 11 according to the first embodiment of the present invention. FIG. 1B is an enlarged view of the periphery of the permanent magnet provided in the magnet slot of the rotor core 25 in the first rotating electrical machine 11 shown in FIG. 1A. FIG. 2 is a longitudinal sectional view showing a part of the first rotating electrical machine 11.

  As shown in FIGS. 1A and 2, the first rotating electrical machine 11 according to the first embodiment of the present invention is configured to include an annular stator 13 and a rotor 17 provided on a rotating shaft 15. Yes.

  As shown in FIG. 2, the stator 13 having a cylindrical outer peripheral surface is attached to the inner peripheral surface of a housing 19 having a cylindrical inner space. The rotating shaft 15 of the rotor 17 is pivotally supported on the side walls 19a and 19b of the housing 19 via a pair of bearings 20a and 20b, respectively. The stator 13 includes a stator core 21 and a stator coil 23 provided on the stator core 21.

  As shown in FIGS. 1A and 2, the stator core 21 is formed in a cylindrical shape as a whole. The stator core 21 is configured by, for example, laminating a plurality of electromagnetic steel plates formed in an annular shape in the axial direction. As shown in FIG. 1A and FIG. 1B, a stator coil 23 is provided in each of the plurality of slots 22 provided in the stator core 21.

  As shown in FIGS. 1A and 2, the rotor 17 is rotatably provided in a hollow portion existing on the inner diameter side of the stator 13 through a slight gap G (see FIG. 2). As illustrated in FIG. 2, the rotor 17 includes a rotor core 25 and a pair of end face plates (a first end face plate 27 a and a second end face plate 27 b) 27. The first end face plate 27a and the second end face plate 27b are formed of a nonmagnetic metal material such as nonmagnetic stainless steel (SUS305) or aluminum, for example.

  Hereinafter, when the first end face plate 27a and the second end face plate 27b are collectively referred to, they may be simply referred to as “end face plates 27”.

  As shown in FIGS. 1A and 2, the rotor core 25 is formed in a cylindrical shape as a whole. The rotor core 25 may be configured by, for example, laminating a plurality of electromagnetic steel plates 25a (see FIG. 2) formed in an annular shape in the axial direction.

  As shown in FIGS. 1A, 1B, and 2, the rotor core 25 has a plurality of sets of magnet slots 29 penetrating in the axial direction (see FIGS. 1A and 2) at equal intervals in the circumferential direction (see FIG. 1A). Is provided. A permanent magnet 31 is inserted and fixed in the magnet slot 29. The cross section of the pair of magnet slots 29 is formed in, for example, a substantially V shape that opens outward in the radial direction of the rotor core 25 (see FIGS. 1A and 1B).

  In the first rotating electrical machine 11, when a motor current is passed through the stator coil 23, a rotating magnetic field is generated in the stator 13. Thus, the rotor 17 is rotationally driven by the interaction between the rotating magnetic field generated in the stator 13 and the magnetic field generated by the permanent magnet 31 (see FIG. 1B) provided in the magnet slot 29 of the rotor core 25.

  As shown in FIG. 1B, the set of magnet slots 29 is configured by combining three slots (a first slot 29a, a second slot 29b, and a third slot 29c). Hereinafter, when the first slot 29a, the second slot 29b, and the third slot 29c are collectively referred to, they may be simply referred to as “magnet slot 29”.

  As shown in FIG. 1B, each of the first slot 29a, the second slot 29b, and the third slot 29c constituting the magnet slot 29 has a pair of permanent magnets (first magnet 31a and second magnet 31b). , The third magnet 31c) is inserted. Hereinafter, when the first magnet 31a, the second magnet 31b, and the third magnet 31c are collectively referred to, they may be simply referred to as “permanent magnets 31”.

  Although it does not specifically limit as the permanent magnet 31, For example, rare earth magnets, such as a neodymium magnet which has a high magnetic characteristic, can be used suitably aiming at high torque density.

  The length of the permanent magnet 31 is set to a length equivalent to the entire length of the rotor core 25 in the axial direction (see FIG. 2).

In the rotor core 25, a magnetic pole portion 33 is constituted by a set of magnet slots 29 and permanent magnets 31.

Of the first slot 29a constituting a part of the magnet slot 29, the portion facing the inner diameter side wall portion 31a1 of the first magnet 31a has a first along the shape of the inner diameter side wall portion 31a1 as shown in FIG. 1B. A continuous wall portion 29a1 is formed. In the magnetization direction (radial direction) of the first magnet 31a, the dimension of the first magnet 31a is set to a value that is equal to or slightly smaller than the minimum dimension of the first slot 29a.

  Thereby, when it accommodates in the 1st slot 29a, the internal-diameter side wall part 31a1 of the 1st magnet 31a is comprised so that it may contact | adhere substantially with respect to the 1st continuous wall part 29a1 of the 1st slot 29a. .

  Similarly to the above, in the second slot 29b that constitutes a part of the magnet slot 29, the portion of the second magnet 31b facing the inner diameter side wall 31b1 has a shape of the inner diameter side wall 31b1 as shown in FIG. 1B. The 2nd continuous wall part 29b1 along is formed. Further, in the magnetization direction of the second magnet 31b, the dimension of the second magnet 31b is set to a value that is equal to or slightly smaller than the minimum dimension of the second slot 29b.

  Similarly, in the third slot 29c constituting a part of the magnet slot 29, the portion facing the inner diameter side wall 31c1 of the third magnet 31c has the shape of the inner diameter side wall 31c1 as shown in FIG. 1B. A third continuous wall portion 29c1 is formed. In the magnetization direction of the third magnet 31c, the dimension of the third magnet 31c is set to a value that is equal to or slightly smaller than the minimum dimension of the third slot 29c.

  Thereby, the inner diameter side wall 31b1 of the second magnet 31b when accommodated in the second slot 29b and the inner diameter side wall 31c1 of the third magnet 31c when accommodated in the third slot 29c are respectively connected to the second slot 29b. The second continuous wall portion 29b1 and the third continuous wall portion 29c1 of the third slot 29c are substantially in close contact with each other.

  On the other hand, in the magnetization orthogonal direction orthogonal to the magnetization direction (radial direction) of the first magnet 31a, the dimension of the first magnet 31a is set to a smaller value than the minimum dimension of the first slot 29a.

  Thereby, the first magnet 31a when accommodated in the first slot 29a is disposed with a gap with respect to the inner wall portion of the first slot 29a in the magnetization orthogonal direction. When accommodated in the first slot 29a, a space formed between the inner wall portion of the first slot 29a and the outer wall portion of the first magnet 31a is filled with a heat resistant resin (not shown). Thereby, the 1st magnet 31a is fixed to the 1st slot 29a. This will be described in detail later.

  Similarly, in the magnetization orthogonal direction orthogonal to the magnetization direction of the second magnet 31b, the dimension of the second magnet 31b is set to a value smaller than the minimum dimension of the second slot 29b. Further, in the magnetization orthogonal direction orthogonal to the magnetization direction of the third magnet 31c, the dimension of the third magnet 31c is set to a smaller value than the minimum dimension of the third slot 29c.

  As a result, the second magnet 31b when accommodated in the second slot 29b and the third magnet 31c when accommodated in the third slot 29c respectively have the second slot 29b and the third slot in the perpendicular direction of magnetization. It arrange | positions with an air gap with respect to the inner wall part of 29c.

  When accommodated in the second slot 29b, a space formed between the inner wall portion of the second slot 29b and the outer wall portion of the second magnet 31b is filled with a heat resistant resin. Similarly, when accommodated in the third slot 29c, a space formed between the inner wall portion of the third slot 29c and the outer wall portion of the third magnet 31c is filled with a heat resistant resin.

As a result, the second magnet 31b is fixed to the second slot 29b, and the third magnet 31c is fixed to the third slot 29c.
[Positioning and fixing structure of permanent magnet 31 used in first rotating electrical machine 11]
Next, the positioning and fixing structure of the permanent magnet 31 used in the first rotating electrical machine 11 will be described in detail with reference to FIGS. 3A and 3B.

FIG. 3A is a perspective view showing a state in which the relative positional relationship between the hole 37 provided in the end face plate 27 provided in the rotor 17 of the first rotating electrical machine 11 and the intermediate member 35 is matched. FIG. 3B is a perspective view conceptually expanding and expressing the relative positional relationship between the hole 37 provided in the end face plate 27 shown in FIG. 3A, the intermediate member 35, and the permanent magnet 31 to which the intermediate member 35 is joined. It is.

  As shown in FIGS. 2 and 3B, intermediate members 35 are joined to both ends of the permanent magnet 31 in the axial direction. This joining is performed through an adhesive 39 (see FIG. 3B; a heat-resistant resin may be used). The intermediate member 35 serves to contribute to the manufacture of the rotor 17 by assisting the positioning of the permanent magnet 31 with respect to the magnet slot 29 provided in the rotor core 25.

  The set of intermediate members 35 is configured by a combination of a first intermediate member 35a, a second intermediate member 35b, and a third intermediate member 35c. The first intermediate member 35a is joined to both ends of the first magnet 31a. The second intermediate member 35b is joined to both ends of the second magnet 31b. The third intermediate member 35c is joined to both ends of the third magnet 31c.

  Hereinafter, the first intermediate member 35a, the second intermediate member 35b, and the third intermediate member 35c may be simply referred to as “intermediate member 35” in some cases.

  As shown in FIG. 3B, the shape / size related to the cross section of the intermediate member 35 is set to be equal to the shape (rectangular shape in the example of FIG. 3B) / size related to the cross section of the permanent magnet 31, for example. Also, the size of the intermediate member 35 in the insertion direction (see FIG. 3B) is set to be equivalent to the size in the depth direction of the hole 37 provided in the end face plate 27, as shown in FIG. 3B, for example. Yes.

  As the material of the intermediate member 35, for example, it is assumed that the first rotating electrical machine 11 is used as a motor for a vehicle in addition to exhibiting a low relative permeability relative to the rotor core 25 made of an electromagnetic steel plate. Then, what has heat resistance, oil resistance, and chemical resistance is preferable. Specifically, as the material of the intermediate member 35, for example, any one of aluminum, aromatic polyether ketone, PA6 resin, or a combination thereof may be selected as appropriate.

  In order to assist the positioning of the permanent magnet 31 with respect to the magnet slot 29 provided in the rotor core 25, as shown in FIG. 3A, a set of intermediate members 35 fitted on the side of the end face plate 27 facing the rotor core 25. A hole 37 is provided. As shown in FIG. 3A, the pair of holes 37 are formed so as to be recessed with respect to the general surface of the end plate 27 on the flat plate.

  The set of holes 37 is configured by a combination of a first hole 37a, a second hole 37b, and a third hole 37c. A first intermediate member 35a joined to both ends of the first magnet 31a is fitted in the first hole 37a. The second intermediate member 35b joined to both ends of the second magnet 31b is fitted into the second hole 37b. The third hole 37c is fitted with a third intermediate member 35c joined to both ends of the third magnet 31c.

  Hereinafter, when the first hole 37a, the second hole 37b, and the third hole 37c are collectively referred to, they may be simply referred to as “holes 37”.

  As shown in FIGS. 3A and 3B, the shape and size related to the cross section of the hole 37 are set to be equal to the shape (rectangular shape in the example of FIG. 3B) and size related to the cross section of the permanent magnet 31, for example. ing. Further, as shown in FIG. 3B, the size of the hole 37 in the depth direction is set to be equal to the size of the insertion direction of the intermediate member 35, for example.

In the positioning and fixing structure of the permanent magnet 31 used in the first rotating electrical machine 11, for example, in a state where the inner diameter side wall portion 31 a 1 of the first magnet 31 a is in contact with (adhered to) the first continuous wall portion 29 a 1 of the first slot 29 a. The first magnet 31a is accommodated in the first slot 29a. In the magnetization direction (radial direction) of the first magnet 31a, a gap is substantially formed between the first slot 29a (magnet slot) and the first magnet 31a (permanent magnet) of the rotor core 25 in the example shown in FIG. 1B. Has not occurred.

In the first rotating electrical machine 11, the positioning of the permanent magnet 31 with respect to the magnet slot 29 of the rotor core 25 is performed by fitting the intermediate member 35 joined to one end of the permanent magnet 31 into the hole 37 provided in the end face plate 27. By matching, one end of the permanent magnet 31 is positioned on the end face plate 27 via the intermediate member 35.

Here, a phenomenon that occurs when a neodymium magnet is employed as the permanent magnet 31 and occurs when the positioning portion of the permanent magnet 31 is provided in the magnet slot 29 will be described.

  The linear expansion coefficient of the neodymium magnet differs between the magnetization direction (radial direction; see FIG. 1B) and the magnetization perpendicular direction (circumferential direction). Specifically, the linear expansion coefficient of the neodymium magnet takes a positive value in the magnetization direction and takes a negative value in the magnetization perpendicular direction.

  Therefore, for example, in an environment of extremely low temperature (for example, about minus 40 degrees Celsius), the neodymium magnet expands in the magnetization perpendicular direction (circumferential direction), whereas the rotor core 25 made of an electromagnetic steel sheet contracts. As a result, stress is generated in the contact portion between the neodymium magnet and the positioning portion provided in the magnet slot 29 of the rotor core 25. Therefore, in the existing technology according to Patent Document 1 (WO2015 / 076045), an R-shaped relief portion is provided in the vicinity of the positioning portion in order to release the stress generated in the contact portion.

  However, in the existing technology according to Patent Document 1, since an R-shaped relief portion is provided in the vicinity of the corner of the permanent magnet in the magnet slot 29 of the rotor core 25, a gap is generated between the permanent magnet and the rotor core. As a result, the magnetic resistance increases due to the influence of the air gap, which may cause a decrease in torque density.

On the other hand, in the first rotating electrical machine 11 (of the rotor 17), the intermediate member 35 joined to one end of the permanent magnet 31 is fitted into the hole 37 provided in the end face plate 27, so that the rotor core Since the permanent magnet 31 is positioned relative to the 25 magnet slots 29, the torque density can be improved with a relatively simple configuration (excluding the permanent magnet positioning portion and the R-shaped relief portion in the magnet slot). .
[Method of manufacturing rotor of first rotating electrical machine 11]
Next, a method for manufacturing the rotor of the first rotating electrical machine 11 will be described with reference to FIG.

  FIG. 4 is a process diagram illustrating a rotor manufacturing method of the first rotating electrical machine 11.

  As shown in FIG. 4, the rotor manufacturing method of the first rotating electrical machine 11 has a relative positional relationship between a magnet slot 29 provided in the rotor core 25 and a hole portion 37 provided in one end face plate 27 facing the rotor core 25. After the step of aligning (step s11) and the step of aligning the relative positional relationship, the inner wall side portions 31a1, 31b1, 31a1, 31b1, of the permanent magnet 31 on the continuous wall portions 29a1, 29b1, 29c1 (see FIG. 1B) of the magnet slot 29 In a state where 31c1 (see FIG. 1B) is in contact, the permanent magnet 31 to which the intermediate member 35 is bonded is inserted into the magnet slot 29 with the intermediate member 35 facing the front, and the intermediate member 35 is When the permanent magnet 31 is received in the magnet slot 29 after the step of fitting into the hole 37 (step s12) and the step of fitting the intermediate member 35 into the hole 37. A step of filling a heat-resistant resin into the gap created between the magnet slots 29 and permanent magnet 31 (step s13), the.

  Further, as shown in FIG. 4, the rotor manufacturing method of the first rotating electrical machine 11 is performed after the step of filling the heat resistant resin, and after the heat resistant resin is cured, The step of aligning the relative positional relationship between the inserted and fixed permanent magnet 31 and the hole 37 provided in the other end face plate 27 facing the rotor core 25 (step s14), and the step of aligning the relative positional relationship Thereafter, the intermediate member 35 joined to the permanent magnet 31 is fitted into the hole 37 provided in the other end face plate 27 (step s15), and the rotor core 25 is sandwiched between the pair of end face plates 27. A step of attaching the rotating shaft 15 to the rotor 17 (step s16) may be adopted.

  As the heat resistant resin, in addition to being excellent in mechanical strength after curing, a resin having oil resistance and chemical resistance is preferable, assuming that the first rotating electrical machine 11 is used as a motor for a vehicle. Although it does not specifically limit as said heat resistant resin, For example, an epoxy resin can be used suitably.

In the method of manufacturing the rotor of the first rotating electrical machine 11, the positioning of the permanent magnet 31 with respect to the magnet slot 29 of the rotor core 25 is performed by an intermediate portion bonded to one end of the permanent magnet 31 in the hole 37 provided in the end face plate 27. This is accomplished by positioning one end of the permanent magnet 31 on the end face plate 27 via the intermediate member 35 by fitting the member 35 together.
According to the rotor manufacturing method of the first rotating electrical machine 11, the positioning of the permanent magnet 31 with respect to the magnet slot 29 of the rotor core 25 is performed by positioning one end of the permanent magnet 31 on the end face plate 27 via the intermediate member 35. Therefore, the rotor 17 of the first rotating electrical machine 11 capable of improving the torque density can be manufactured by a relatively simple process.

[Configuration of the second rotating electrical machine 41 according to the second embodiment of the present invention]
Next, the second rotating electrical machine 41 according to the second embodiment of the present invention will be described in detail with reference to FIGS. 5A and 5B.

  FIG. 5A is a front view illustrating the overall configuration of the second rotating electrical machine 41 according to the second embodiment of the present invention. FIG. 5B is an enlarged view of the periphery of the permanent magnet provided in the magnet slot of the rotor core 47 in the second rotating electrical machine 41 shown in FIG. 5A.

  The main differences between the first rotating electrical machine 11 according to the first embodiment of the present invention and the second rotating electrical machine 41 according to the second embodiment of the present invention are shown in comparison with FIGS. 1B and 5B. The number and shape of the magnet slots 56, 57, 58, and 59, and the number and shape of the permanent magnets 65, 66, 67, and 68.

  As shown in FIG. 5A, the second rotating electrical machine 41 according to the second embodiment of the present invention is configured to include an annular stator 43 and a rotor 47 provided on the rotating shaft 45.

  As shown in FIG. 5A, the stator 43 having a cylindrical outer peripheral surface includes a stator core 51 and a stator coil 53 provided on the stator core 51.

  As shown in FIG. 5A, the stator core 41 is formed in a cylindrical shape as a whole. The stator core 41 is configured by, for example, laminating a plurality of electromagnetic steel plates formed in an annular shape in the axial direction. As shown in FIG. 5A, a stator coil 53 is provided in each of the plurality of slots 52 provided in the stator core 41.

  As shown in FIG. 5A, the rotor 47 includes a rotor core 55 and a pair of end face plates 71 (see FIG. 6).

  As shown in FIGS. 5A and 5B, the rotor core 55 has a plurality of sets of magnet slots 56, 57, 58, 59 penetrating in the axial direction (see FIG. 5A) at equal intervals in the circumferential direction (see FIG. 5A). It is provided. Permanent magnets 65, 66, 67, and 68 are inserted and fixed in the magnet slots 56, 57, 58, and 59, respectively. The cross section of the pair of magnet slots 56, 57, 58, 59 is, for example, formed in an arc shape that opens in two steps toward the outside in the radial direction (see FIGS. 5A and 5B) of the rotor core 55 as a whole.

  In the second rotating electric machine 41, when a motor current is passed through the stator coil 53, a rotating magnetic field is generated in the stator 43. The rotating magnetic field generated in the stator 43 in this manner interacts with the magnetic field generated by the permanent magnets 65, 66, 67, 68 (see FIG. 5B) provided in the magnet slots 56, 57, 58, 59 of the rotor core 55, respectively. The rotor 47 is driven to rotate.

  As shown in FIG. 5B, the set of magnet slots 56, 57, 58, 59 includes four arc slots (first arc slot 56, second arc slot 57, third arc slot 58, and fourth arc slot 59). It is configured by combining.

  As shown in FIG. 5B, each of the magnet slots 56, 57, 58, 59 has a pair of permanent magnets (a first arc magnet 65, a second arc magnet 66, a third arc magnet 67, a fourth magnet). An arc magnet 68) is inserted.

In the rotor core 55, a magnetic pole portion 63 (see FIG. 5B) is configured by a set of magnet slots 56, 57, 58, 59 and permanent magnets 65, 66, 67, 68.

As shown in FIG. 5B, in the first arc slot 56, the portion of the first arc magnet 65 facing the inner diameter side wall 65a faces the first arc continuous wall 56a along the arc shape of the inner diameter side wall 65a. Is formed.

  Similarly, a portion of the second arc slot 57 facing the inner diameter side wall 66a of the second arc magnet 66 has a second arc continuous wall along the arc shape of the inner diameter side wall 66a as shown in FIG. 5B. A portion 57a is formed.

  Similarly, in a portion of the third arc slot 58 where the inner diameter side wall 67a of the third arc magnet 67 faces, as shown in FIG. 5B, a third arc continuous wall along the arc shape of the inner diameter side wall 67a. A portion 58a is formed.

  Similarly, in the fourth arc slot 59, the portion of the fourth arc magnet 68 facing the inner diameter side wall 68a faces the fourth arc continuous wall along the arc shape of the inner diameter side wall 68a as shown in FIG. 5B. A portion 59a is formed.

  The first arc magnet 65 when accommodated in the first arc slot 56 is disposed with a gap with respect to the inner wall portion of the first arc slot 56 in the arc direction.

  Similarly, the second arc magnet 66 when accommodated in the second arc slot 57 is disposed with a gap with respect to the inner wall portion of the second arc slot 57 in the arc direction.

  Similarly, the third arc magnet 67 when accommodated in the third arc slot 58 is disposed with a gap with respect to the inner wall portion of the third arc slot 58 in the arc direction.

  Similarly, the fourth arc magnet 68 when accommodated in the fourth arc slot 59 is disposed with a gap with respect to the inner wall portion of the fourth arc slot 59 in the arc direction.

The aforementioned gap in the arc direction is filled with epoxy resin as in the first embodiment. Accordingly, the first arc magnet 65 is set to the first arc slot 56, the second arc magnet 66 is set to the second arc slot 57, the third arc magnet 67 is set to the third arc slot 58, and the fourth The fourth arc magnets 68 are fixed to the arc slots 59, respectively.
[Positioning and fixing structure of permanent magnets 65, 66, 67, 68 used in second rotating electrical machine 41]
Next, the positioning and fixing structure of the permanent magnets 65, 66, 67, 68 used in the second rotating electrical machine 41 will be described in detail with reference to FIG.

FIG. 6 is a perspective view showing a state in which the relative positional relationship between the hole 75 provided in the end face plate 71 provided in the rotor 47 of the second rotating electrical machine 41 and the intermediate member 73 is aligned.

As shown in FIG. 6, the 1st circular arc intermediate member 73a is joined to the axial direction both ends of the 1st circular arc magnet 65 using an epoxy resin. Similarly, the second arc intermediate member 73b is joined to both ends of the second arc magnet 66 in the axial direction using an epoxy resin. Similarly, the third arc intermediate member 73c is joined to both ends of the third arc magnet 67 in the axial direction using an epoxy resin. Similarly, the fourth arc intermediate member 73d is joined to both ends of the fourth arc magnet 68 in the axial direction using an epoxy resin. Hereinafter, the first arc intermediate member 73a, the second arc intermediate member 73b, the third arc intermediate member 73c, and the fourth arc intermediate member 73d may be simply referred to as “intermediate member 73”.

The intermediate member 73 serves to contribute to the manufacture of the rotor 47 by assisting the positioning of the permanent magnets 65, 66, 67, 68 with respect to the magnet slots 56, 57, 58, 59 provided in the rotor core 55.

  As in the first embodiment, the shape / size related to the cross section of the intermediate member 73 is set to be the same as the shape / size related to the cross section of the permanent magnets 65, 66, 67, 68, for example, as shown in FIG. Has been. The size in the insertion direction of the intermediate member 73 is also set to be equal to the size in the depth direction of the hole 75 provided in the end face plate 71, as in the first embodiment.

  In order to assist the positioning of the permanent magnets 65, 66, 67, 68 with respect to the magnet slots 56, 57, 58, 59 provided in the rotor core 55, the side of the end face plate 71 facing the rotor core 55 is shown in FIG. Thus, a set of hole portions 75 in which the intermediate member 73 is fitted are provided. As shown in FIG. 6, the pair of holes 75 are formed so as to be recessed with respect to the general surface of the end plate 71 on the flat plate.

  The set of holes 75 is configured by a combination of a first arc hole 75a, a second arc hole 75b, a third arc hole 75c, and a fourth arc hole 75d.

  Hereinafter, when the first arc hole 75a, the second arc hole 75b, the third arc hole 75c, and the fourth arc hole 75d are collectively referred to, they may be simply referred to as “holes 75”.

  A first arc intermediate member 73a joined to both ends of the first arc magnet 65 is fitted into the first arc hole 75a.

  Similarly, second arc intermediate members 73b respectively joined to both ends of the second arc magnet 66 are fitted into the second arc hole 75b.

  Similarly, a third arc intermediate member 73c joined to both ends of the third arc magnet 67 is fitted into the third arc hole 75c.

  Similarly, a fourth arc intermediate member 73d that is joined to both ends of the fourth arc magnet 68 is fitted into the fourth arc hole 75d.

  The shape and size related to the cross section of the hole 75 are set to be the same as the shape and size related to the cross section of the permanent magnets 65, 66, 67, and 68, for example, as in the first embodiment. In addition, as shown in FIG. 6, the size of the hole 75 in the depth direction is set to be equal to the size of the intermediate member 73 in the insertion direction, for example.

In the positioning and fixing structure of the permanent magnets 65, 66, 67, 68 used in the second rotating electrical machine 41, for example, the inner diameter side wall portion 65 a of the first arc magnet 65 is formed on the first arc continuous wall portion 56 a of the first arc slot 56. The first arc magnet 65 is accommodated in the first arc slot 56 in a state in which the first arc slots 56 are in contact with each other.

In the second rotating electrical machine 41, the permanent magnets 65, 66, 67, 68 are positioned with respect to the magnet slots 56, 57, 58, 59 of the rotor core 55 in the holes 75 provided in the end face plate 71. , 67, 68 are fitted into the intermediate member 73, so that one end of the permanent magnets 65, 66, 67, 68 is positioned on the end face plate 71 via the intermediate member 75. It is accomplished by that.

Here, a neodymium magnet is employed as the permanent magnet 31, and arc-shaped permanent magnets 65, 66, 67 and 68 are provided in the arc-shaped magnet slots 56, 57, 58 and 59, and the permanent magnet 31 is permanent. The phenomenon that occurs when the positioning portions of the magnets 65, 66, 67, and 68 are provided will be described.

  As described above, the linear expansion coefficient of the neodymium magnet takes a positive value in the magnetization direction (radial direction) and takes a negative value in the magnetization perpendicular direction (circumferential direction).

  Therefore, for example, in an environment of extremely low temperature (for example, about minus 40 degrees Celsius), the neodymium magnet expands in the magnetization perpendicular direction (circumferential direction), whereas the rotor core 55 made of an electromagnetic steel sheet contracts. As a result, stress is generated at the contact portion between the neodymium magnet and the positioning portion provided in the magnet slots 56, 57, 58, 59 of the rotor core 55. Therefore, in the existing technology, an R-shaped relief portion is provided in the vicinity of the positioning portion in order to release the stress generated in the contact portion.

  However, in the existing technology, since the R-shaped relief portions are provided in the vicinity of the corners of the permanent magnets 65, 66, 67, 68 among the magnet slots 56, 57, 58, 59 of the rotor core 55, the permanent magnet and the rotor core A gap is generated between the two. As a result, the magnetic resistance increases due to the influence of the air gap, which may cause a decrease in torque density.

  On the other hand, in the second rotating electrical machine 41 (the rotor 47), the intermediate member 73 joined to one end of the permanent magnets 65, 66, 67, 68 is inserted into the hole 75 provided in the end face plate 71. In order to perform the positioning of the permanent magnets 65, 66, 67, 68 with respect to the magnet slots 56, 57, 58, 59 of the rotor core 55 by fitting together, a relatively simple configuration (magnet slot) as in the first embodiment. The torque density can be improved by removing the permanent magnet positioning part and the R-shaped relief part.

[Operation of rotor of rotating electrical machine according to the present invention]
Next, the operation of the rotor of the rotating electrical machine according to the present invention will be described by illustrating the operation of the rotor 17 of the first rotating electrical machine 11 according to the first embodiment of the present invention.

In the rotor 17 of the first rotating electrical machine 11 based on the first aspect of the present invention, for example, the inner diameter side wall portion 31a1 of the first magnet 31a contacts (adheres) to the first continuous wall portion 29a1 of the first slot 29a. In the state, the first magnet 31a is accommodated in the first slot 29a.

  In the first rotating electrical machine 11, the positioning of the permanent magnet 31 with respect to the magnet slot 29 of the rotor core 25 is performed by an intermediate member 35 joined to one end of the permanent magnet 31 in a hole 37 provided in the end face plate 27. Is achieved by positioning one end portion of the permanent magnet 31 on the end face plate 27 via the intermediate member 35.

  According to the rotor 17 of the first rotating electrical machine 11 based on the first aspect, the torque density can be improved with a relatively simple configuration (excluding the permanent magnet positioning portion and the R-shaped relief portion in the magnet slot). Can do.

  Furthermore, in the rotor 17 of the first rotating electrical machine 11 based on the first aspect, in the magnetization direction (radial direction) of the permanent magnet 31, the size of the permanent magnet 31 is equal to or slightly smaller than the minimum size of the magnet slot 29. If a configuration in which the inner diameter side wall portion of the permanent magnet 31 abuts (closely contacts) the continuous wall portion of the magnet slot 29 by adopting a small value is set, the following effects can be expected.

  That is, it is possible to eliminate the resin injection hole formed by transfer molding provided to attract the permanent magnet 31 accommodated in the magnet slot 29 toward the inner diameter side (if necessary). As a result, the torque density can be improved and the demagnetization resistance can be improved (because the permeance coefficient is increased).

Furthermore, according to the rotor 17 of the first rotating electrical machine 11 based on the first aspect, the positioning accuracy of the permanent magnet 31 with respect to the magnet slot 29 provided in the rotor core 25 can be improved. In short, it is possible to improve the accuracy of overlapping the center of the magnet slot 29 in the circumferential direction and the center of the permanent magnet 31 in the circumferential direction. As a result, performance variations (torque density, torque ripple, etc.) that inevitably occur in the manufacturing process can be suppressed.

Further, in the rotor 17 of the first rotating electrical machine 11 based on the second aspect of the present invention, the intermediate member 35 is joined to both ends of the permanent magnet 31 in the rotation axis direction, and the pair of end face plates 27 are respectively connected. Is provided with a hole 37 in which the intermediate member 35 is fitted, and the intermediate member 35 is fitted in the hole 37 so that both ends of the permanent magnet 31 in the rotation axis direction are paired via the intermediate member 35. Each of the end face plates 27 is positioned.

Further, in the rotor 17 of the first rotating electrical machine 11 based on the third aspect of the present invention, when the permanent magnet 31 is accommodated in the magnet slot 29, the gap generated between the magnet slot 29 and the permanent magnet 31 is Filled with heat resistant resin.

According to the rotor 17 of the first rotating electrical machine 11 based on the third aspect, when the permanent magnet 31 is accommodated in the magnet slot 29, a heat-resistant resin is formed in the gap generated between the magnet slot 29 and the permanent magnet 31. Since it is filled, the permanent magnets 31 positioned on the pair of end face plates 27 via the intermediate member 35 can be firmly fixed to the magnet slots 29 of the rotor core 25.

In the rotor 17 of the first rotating electrical machine 11 according to the fourth aspect of the present invention, the material of the intermediate member 35 is any one of aluminum, aromatic polyetherketone, PA6 resin, or a combination thereof. Selected.

Moreover, the 1st rotary electric machine 11 based on the 5th viewpoint of this invention has the rotor 17 of the 1st rotary electric machine 11 based on the 1st-4th viewpoint, and the cylindrical shape which has the stator core 21 in which the stator coil 23 was provided. The stator 13 is provided.

  According to the first rotating electrical machine 11 based on the fifth aspect, the torque density can be improved with a relatively simple configuration (excluding the permanent magnet positioning portion and the R-shaped relief portion in the magnet slot).

  The rotor manufacturing method for the rotating electrical machine 11 according to the sixth aspect of the present invention is based on the relative relationship between the magnet slot 29 provided in the rotor core 25 and the hole 37 provided in the one end face plate 27 facing the rotor core 25. After the step of aligning the positional relationship (step s11) and the step of aligning the relative positional relationship, the inner wall portions 31a1, 31a1, 31a1, 29a1, 29b1, 29c1 of the magnet slot 29 (see FIG. 1B) In a state where 31b1 and 31c1 (see FIG. 1B) are in contact with each other, the permanent magnet 31 to which the intermediate member 35 is bonded is inserted into the magnet slot 29 with the intermediate member 35 facing toward the head, and the intermediate member After the step of fitting 35 into the hole 37 (step s12) and the step of fitting the intermediate member 35 into the hole 37, the permanent magnet 31 is accommodated in the magnet slot 29. Having a step (step s13) filling the heat-resistant resin into the gap created between the magnet slots 29 and permanent magnets 31 when it is.

  In the rotor manufacturing method of the rotating electrical machine 11 based on the sixth aspect, the positioning of the permanent magnet 31 with respect to the magnet slot 29 of the rotor core 25 is performed in the hole portion 37 provided in the end face plate 27 in one end portion of the permanent magnet 31. As the joined intermediate member 35 is fitted, one end of the permanent magnet 31 is positioned on the end face plate 27 via the intermediate member 35.

According to the rotor manufacturing method of the rotating electrical machine 11 based on the sixth aspect, one end portion of the permanent magnet 31 is positioned on the end face plate 27 via the intermediate member 35, thereby making the permanent magnet core 29 permanent with respect to the rotor core 25. Since the positioning of the magnet 31 is performed, the rotor 17 of the first rotating electrical machine 11 capable of improving the torque density can be manufactured by a relatively simple process.
[Other Embodiments]
The plurality of embodiments described above show examples of realization of the present invention. Therefore, the technical scope of the present invention should not be limitedly interpreted by these. This is because the present invention can be implemented in various forms without departing from the gist or main features thereof.

  For example, in the description of the first rotating electrical machine 11 according to the first embodiment of the present invention, the shape / size related to the cross section of the intermediate member 35 is set to be equal to the shape / size related to the cross section of the permanent magnet 31. However, the present invention is not limited to this example.

  The shape and size of the cross section of the intermediate member 35 may be any shape and size as long as the intermediate member 35 can be satisfactorily joined to the end of the permanent magnet 31 via the heat resistant resin.

  Moreover, in description of the 1st rotary electric machine 11 which concerns on 1st Embodiment of this invention, the size which concerns on the insertion direction (refer FIG. 3B) of the intermediate member 35 is the depth direction of the hole part 37 provided in the end surface board 27. FIG. Although an example in which the size is set to be equivalent to the size has been described, the present invention is not limited to this example.

  The size in the insertion direction of the intermediate member 35 may be any size as long as the performance of the first rotating electrical machine 11 can be maintained satisfactorily.

  Similarly, in the description of the second rotating electrical machine 41 according to the second embodiment of the present invention, the shape / size related to the cross section of the intermediate member 73 is changed to the shape / size related to the cross section of the permanent magnets 65, 66, 67, 68. Although an example in which the size is set equal to the size has been described, the present invention is not limited to this example.

  The shape and size of the cross-section of the intermediate member 73 may be any shape and size as long as it can satisfactorily perform the bonding with the end portions of the permanent magnets 65, 66, 67, and 68 through the heat-resistant resin. It doesn't matter.

  Similarly, in the description of the second rotating electrical machine 41 according to the second embodiment of the present invention, the size in the insertion direction of the intermediate member 73 is the size in the depth direction of the hole 75 provided in the end face plate 71. Although an example of setting the same has been described, the present invention is not limited to this example.

  The size of the intermediate member 73 in the insertion direction may be any size as long as the performance of the second rotating electrical machine 41 can be maintained satisfactorily.

  In addition, the present invention provides a permanent magnet arrangement structure (for example, the number of permanent magnets, multistage arrangement, etc.), a permanent magnet shape (for example, a rectangular shape, an arc shape), a magnetic pole portion itself, and the like. Needless to say, it is applicable regardless of the quantity.

DESCRIPTION OF SYMBOLS 11 1st rotary electric machine which concerns on 1st Embodiment 13 Stator 15 Rotating shaft 17 Rotor 21 Stator core 23 Stator coil (coil)
25 rotor core 27 end face plate 29 magnet slot 29a1 first continuous wall portion of first slot (continuous wall portion of magnet slot)
29b1 second continuous wall portion of the second slot (continuous wall portion of the magnet slot)
29c1 Third continuous wall portion of the third slot (continuous wall portion of the magnet slot)
31 Permanent magnet 31a1 Inner diameter side wall of first magnet (inner diameter side wall of permanent magnet)
31b1 Inner diameter side wall of second magnet (inner diameter side wall of permanent magnet)
31c1 Inner diameter side wall of third magnet (inner diameter side wall of permanent magnet)
35 Intermediate member 37 Hole 41 Second rotating electrical machine according to second embodiment 43 Stator 45 Rotating shaft 47 Rotor 51 Stator core 53 Stator coil (coil)
55 Rotor core 56, 57, 58, 59 Magnet slot 65, 66, 67, 68 Permanent magnet 71 End face plate 73 Intermediate member 75 Hole

Claims (6)

A rotor core provided with a plurality of magnet slots along the circumferential direction for accommodating permanent magnets extending in the rotation axis direction;

A rotor of a rotating electrical machine including a pair of end face plates respectively provided at end portions in the rotation axis direction of the rotor core, wherein a portion of the magnet slot facing an inner diameter side wall portion of the permanent magnet faces the inner diameter A continuous wall along the shape of the side wall is formed,
An intermediate member exhibiting a low relative permeability compared to the relative permeability according to the rotor core is joined to at least one of the end portions in the rotation axis direction of the permanent magnet,
Of the pair of end face plates, the end face plate on the side facing at least one of the rotation axis direction ends of the permanent magnet is provided with a hole portion into which the intermediate member is fitted.
The permanent magnet is accommodated in the magnet slot in a state in which the inner diameter side wall portion of the permanent magnet is in contact with the continuous wall portion of the magnet slot, and the intermediate member is fitted into the hole portion, whereby the permanent magnet The one end of the rotating shaft in the rotating shaft direction is positioned on an end face plate on the side facing the one through the intermediate member. The rotor of the rotating electrical machine according to claim 1,
The intermediate member is joined to both ends of the permanent magnet in the rotation axis direction,
Each of the pair of end face plates is provided with a hole portion into which the intermediate member is fitted,
By rotating the intermediate member into the hole, both rotation shaft direction end portions of the permanent magnet are positioned on the pair of end face plates via the intermediate member, respectively. Rotor. A rotor for a rotating electrical machine according to claim 1 or 2,
A rotor of a rotating electrical machine, wherein a space formed between the magnet slot and the permanent magnet when the permanent magnet is accommodated in the magnet slot is filled with a heat resistant resin. A rotor of a rotating electrical machine according to any one of claims 1 to 3,
A material for the intermediate member is selected from the group consisting of aluminum, aromatic polyetherketone, PA6 resin, or a combination thereof. The rotor of the rotating electrical machine according to any one of claims 1 to 4,
And a cylindrical stator having a stator core provided with a coil. Rotation comprising a magnet core that accommodates a permanent magnet extending in the direction of the rotation axis and a plurality of rotor cores provided along the circumferential direction, and a pair of end face plates provided respectively at ends of the rotor core in the direction of the rotation axis A method for manufacturing an electric rotor,
In the portion of the magnet slot where the inner diameter side wall portion of the permanent magnet faces, a continuous wall portion is formed along the shape of the inner diameter side wall portion,
An intermediate member exhibiting a low relative permeability compared to the relative permeability according to the rotor core is joined to at least one of the end portions in the rotation axis direction of the permanent magnet,
Of the pair of end face plates, the end face plate on the side facing at least one of the end portions in the rotation axis direction of the permanent magnet is provided with a hole portion into which the intermediate member is fitted.
Aligning the relative positional relationship between the magnet slot provided in the rotor core and the hole provided in the end plate facing the one side;
After the step of aligning the relative positional relationship, with the inner wall of the permanent magnet abutting against the continuous wall of the magnet slot, the permanent magnet joined to the intermediate member is moved to the intermediate member side. And inserting the intermediate member into the hole portion, and
After the step of fitting the intermediate member into the hole, filling the space formed between the magnet slot and the permanent magnet with a heat-resistant resin when the permanent magnet is accommodated in the magnet slot; Have
By fitting the intermediate member into the hole, the one end of the permanent magnet in the rotational axis direction is positioned on the end plate on the side facing the one through the intermediate member. The permanent magnet is fixed to the magnet slot by filling a heat-resistant resin in a gap generated between the magnet slot and the permanent magnet.
A method for manufacturing a rotor of a rotating electrical machine.

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