JP2021045036A - Magnetic wedge and rotary electric machine - Google Patents

Abstract

To provide a magnetic wedge which suppress an increase in leakage magnetic flux, and, a rotary electric machine employing the same.SOLUTION: A magnetic wedge is used for a radial gap type rotary electric machine in which a stator is disposed oppositely to a rotor at a predetermined interval in a radial direction. The magnetic wedge has a principal surface and contains planarly structured flat particles of which the thickness is 10 nm or more and 100 μm or less, the ratio of an average length with respect to the thickness within the principal surface is 5 or more and 10,000 or less and which contain at least one magnetic element selected from among iron (Fe), cobalt (Co) and nickel (Ni). The principal surface is oriented in a rotation direction of the rotary electric machine and disposed substantially vertical to a cavity face between the stator and the rotor, a radial direction coercive force in the rotation direction of the rotary electric machine is lower than a rotation direction coercive force in the rotation direction of the rotary electric machine, and the rotation direction coercive force is lower than an axial direction coercive force in an axial direction of the rotary electric machine.SELECTED DRAWING: Figure 4

Description

Embodiments of the present invention relate to magnetic wedges and rotary electric machines.

Normally, the coil winding of a rotary electric machine is housed in an iron core slot, and is supported and fixed by a wedge provided in the slot opening. A non-magnetic material is generally used as the material of this wedge, but since the magnetic resistance value in the gap between the stator core and the rotor core becomes discontinuous, the surface portion of the iron core facing the wedge through the gap. Pulsation occurs in the magnetic flux distribution of, and the harmonic loss increases. For the purpose of reducing this harmonic loss, a wedge having moderate magnetism (magnetic wedge) is provided. FIG. 1 is a schematic view of the usage state of the magnetic wedge and the effect of the magnetic wedge. In FIG. 1, a radial gap type rotary electric machine is shown as an example.

In FIG. 1, a magnetic wedge 100, a coil 230, an iron core tooth 250, and an iron core slot 260 are shown.

Needless to say, in the case of a magnetic wedge, the higher the magnetic permeability of the magnetic wedge, the more the harmonic loss can be reduced. However, as shown in FIG. 1, since the magnetic wedges are arranged so as to bridge the adjacent iron core teeth, there is a drawback that the leakage flux flowing between the iron core teeth via the magnetic wedge increases. ..

Jikkenhei 4-64956 Gazette

Japanese Unexamined Patent Publication No. 58-19138

Japanese Unexamined Patent Publication No. 52-6906

Japanese Unexamined Patent Publication No. 62-262626

The problem to be solved by the present invention is to provide a magnetic wedge that suppresses an increase in leakage flux and a rotary electric machine using the same.

The magnetic wedge of the embodiment is a magnetic wedge used in a radial gap type rotary electric machine in which stators are arranged to face the rotor at predetermined intervals in the radial direction, and the magnetic wedge has a main surface. , The thickness is 10 nm or more and 100 μm or less, the ratio of the average length in the main surface to the thickness is 5 or more and 10000 or less, and at least selected from the group consisting of iron (Fe), cobalt (Co) and nickel (Ni). It contains flat particles of a planar structure containing one magnetic element, the main surface is oriented along the rotation direction of the rotor, and is arranged substantially perpendicular to the void surface between the stator and the rotor. The radial cohesive force in the radial direction of the rotating electric machine is lower than the rotational coercive force in the rotational direction of the rotating electric machine, and the rotational coercive force is lower than the axial coercive force in the axial direction of the rotating electric machine.

It is a schematic diagram of the usage state of the magnetic wedge and the effect of the magnetic wedge. It is a schematic diagram of the radial gap type rotary electric machine of 1st Embodiment. It is a schematic diagram of the axial gap type rotary electric machine of 1st Embodiment. It is a schematic diagram of the magnetic wedge of the 1st embodiment. It is a schematic diagram explaining the main surface of the magnetic material of 1st Embodiment. It is a schematic diagram which shows the measuring method of magnetic permeability of 1st Embodiment. It is a schematic diagram which shows the use state of the magnetic wedge in the radial gap type rotary electric machine of 1st Embodiment. It is a schematic diagram which shows the use state of the magnetic wedge in the axial gap type rotary electric machine of 1st Embodiment. It is a schematic diagram of the magnetic wedge formed by orienting the magnetic material of the 1st embodiment. It is a schematic diagram for demonstrating the arrangement state of the magnetic material suitable for reducing the leakage flux flowing from the void end portion of the 1st Embodiment to the outside of an iron core. It is a schematic diagram for demonstrating the arrangement state of the magnetic material suitable for reducing the leakage flux flowing through the iron core tooth through the magnetic wedge of 1st Embodiment. It is a conceptual diagram example of the magnetic wedge containing the magnetic material which has the magnetic permeability difference depending on the in-plane direction of 1st Embodiment. It is a schematic diagram of an example of the magnetic material of the first embodiment. It is a schematic diagram which shows the example of the magnetic material which has the concave part or the convex part of the magnetic material of 1st Embodiment. It is a schematic diagram which shows an example of the radial gap type rotary electric machine of 2nd Embodiment. It is a schematic diagram which shows an example of the axial gap type rotary electric machine of 2nd Embodiment. It is a schematic diagram which shows an example of the generator of the 2nd Embodiment. It is a schematic diagram which shows an example of the linear motor of the 2nd Embodiment.

(First Embodiment)
The magnetic wedge of the embodiment is a magnetic wedge used in a rotary electric machine, and includes a magnetic material having a planar structure having a main surface. The main surface of the magnetic material is arranged substantially perpendicular to the gap surface between the stator and rotor of the rotating electric machine. There is a difference in the axial magnetic permeability in the axial direction of the rotary electric machine, the rotational magnetic permeability in the rotational direction, and the radial magnetic permeability in the radial direction.

In the present specification, each of the "axial direction", "rotation direction" and "diameter direction" shall be determined with reference to the rotor of the rotating electric machine. That is, the "axial direction" means the direction along the rotation axis of the rotor, and the "rotation direction" means the circumferential direction (or the tangential direction thereof) around the rotation axis of the rotor. The "diameter direction" means a direction orthogonal to the rotation axis of the rotor.

The "void surface" is defined from the gap between the rotor and the stator. The "void surface" of the radial gap type rotary electric machine and the axial gap type rotary electric machine will be described with reference to FIGS. 2 and 3. FIG. 2 is a schematic view of the radial gap type rotary electric machine of the present embodiment. FIG. 3 is a schematic view of the axial gap type rotary electric machine of the present embodiment.

In FIG. 2, a rotary electric machine 200, a rotor 210, a stator core 220, a coil 230, and an air gap surface 240 are shown.

In FIG. 3, a rotary electric machine 200, a rotor 210, a coil 230, an air gap surface 240, an iron core tooth 250, a stator 270, and a shaft 280 are shown.

In the case of a radial gap type rotary electric machine, as shown in FIG. 2, since the stators are arranged to face the rotor at predetermined intervals in the radial direction, the "void surface" is centered on the rotation axis of the rotor. It is a plane parallel to the cylindrical plane. Therefore, the radial direction is perpendicular to the void surface, and the axial direction and the rotation direction are parallel to the void surface.

On the other hand, in the case of an axial gap type rotary electric machine, as shown in FIG. 3, the stators are arranged to face the rotor at predetermined intervals in the axial direction, so that the "void surface" is orthogonal to the rotation axis of the rotor. It is a side to do. Therefore, the axial direction is perpendicular to the void surface, and the rotation direction and the radial direction are parallel to the void surface.

In the magnetic wedge of the present embodiment, it is preferable that the magnetic permeability in the three directions of the axial magnetic permeability, the rotational magnetic permeability, and the radial magnetic permeability have a difference. The difference ratio is more preferably 10% or more, further preferably 50% or more, still more preferably 100% or more. This is preferable because the increase in leakage flux due to the use of the magnetic wedge can be suppressed and the effect of improving the efficiency of the rotary electric machine can be fully enjoyed. Further, by increasing the effective magnetic flux (main magnetic flux), it is expected that the torque of the rotating electric machine will be improved.

The ratio of the difference in magnetic permeability is defined based on the low magnetic permeability. For example, the ratio of the difference between the radial magnetic permeability μr and the rotational magnetic permeability μθ is calculated when the rotational magnetic permeability is low (μr−μθ) / μθ × 100 (%), and when the radial magnetic permeability is low (). Calculated as μθ−μr) / μr × 100 (%).

FIG. 4 is a schematic view of the magnetic wedge of the present embodiment.

In FIG. 4, the magnetic wedge 100, the magnetic body 2, the first surface 2a, and the void surface 240 are shown.

The magnetic wedge includes a magnetic material having a planar structure having a main surface. As the magnetic material having a planar structure, the magnetic material includes at least one selected from the group consisting of flat particles, ribbons, thin films, thick films, and plate-like members. The flat particles are flat particles (flaky particles, flattened particles) having a flat shape (flaky shape, flattened shape). The thin band (ribbon) is ribbon-shaped with a thickness of several μm to 100 μm, the thin film is a thin film with a thickness of several nm to 10 μm, and the thick film is about several μm to several hundred μm. The thick film and plate-shaped member refer to a plate-shaped member having a thickness of about 100 μm to several hundred mm, but they are not strictly distinguished and may be slightly out of the thickness range. In any case, it is preferable that the average length in the main surface (defined by (a + b) / 2 using the maximum length a and the minimum length b. Details will be described later) is larger than the thickness. The above-mentioned thickness range and classification are only a guide, and whether or not the magnetic material includes flat particles, thin bands (ribbons), thin films, thick films, or plate-like members depends on the appearance. Make a comprehensive judgment including information such as shape.

The "main surface" in the magnetic material is a surface corresponding to a flat surface in a planar structure. FIG. 5 is a schematic view illustrating a main surface of the magnetic material of the present embodiment. For example, in the case of a prism, as shown in FIG. 5A, the surface having the largest area or the surface facing the surface is the main surface. In the case of a prism, the first surface 2a or the second surface 2b is the main surface. In the case of a cylinder, it means the bottom surface as shown in FIG. 5 (b). In the case of a cylinder, the first surface 2a or the second surface 2b is the main surface. In the case of a flat ellipsoid, the main surface is the cross section having the widest area as shown in FIG. 5 (c). In the case of a flat ellipsoid, the first surface 2a is the main surface. In the case of a rectangular parallelepiped, it means the surface having the largest area as shown in FIG. 5 (d). In the case of a rectangular parallelepiped, the first surface 2a or the second surface 2b is the main surface. That is, in the case of flat particles, it refers to a flat surface, in the case of a thin band (ribbon) or a plate, it refers to a plate surface, and in the case of a thin film or a thick film, it refers to a film surface. The surface having the largest area in the prism of FIG. 5 (a), the cylinder of FIG. 5 (b), and the flat ellipsoid of FIG. 5 (c) is defined as the first surface 2a. The second surface 2b is a surface facing the first surface 2a. The main surface is a first surface 2a or a second surface 2b.

Further, it is preferable that the average length in the main surface is larger than the thickness. More preferably, the ratio of the average length in the main surface to the thickness is 5 or more. This is preferable because the magnetic permeability of the magnetic wedge tends to be different (the anisotropy becomes large). From the viewpoint of reducing loss, eddy current loss can be reduced, which is preferable.

The average length in the main surface is defined by (a + b) / 2 using the maximum length a and the minimum length b. The ratio of the average length in the main surface to the thickness is defined by ((a + b) / 2) / t using the maximum length a, the minimum length b, and the thickness t.

From the viewpoint of suppressing the leakage flux, it is preferable that the magnetic material is arranged so as to be substantially perpendicular to the void surface. Although some of the magnetic materials may not be perpendicular to each other, the fact that the main surface of more than half of the magnetic material is within ± 20 ° with respect to the surface perpendicular to the void surface is described in the present embodiment. It is a definition of "substantially vertical", and it is preferable to satisfy "substantially vertical" in this definition. More preferably, the main surface of more than half of the magnetic material is in the range of ± 10 ° with respect to the surface perpendicular to the void surface.

In order to make this configuration easier to understand, FIG. 4A schematically shows the relationship between the main surface and the void surface of the magnetic material. Further, FIG. 4B illustrates the angle formed by the straight line perpendicular to the void surface and the main surface of the magnetic material included in the magnetic wedge.

Although flat particles are used as the magnetic material in FIGS. 4 (a) and 4 (b), a magnetic material such as a thin band (ribbon), a thin film, a thick film, or a plate-shaped member may be used. With such a configuration, the magnetic permeability of the magnetic wedge is high in the direction perpendicular to the void surface and low in the direction parallel to the void surface, so that the increase in leakage flux due to the use of the magnetic wedge is suppressed and the efficiency of the rotating electric machine is improved. It is preferable that the effect can be fully enjoyed. In addition, the effective magnetic flux (main magnetic flux) can be increased to improve the torque of the rotating electric machine.

The magnetic permeability of the present embodiment is a true magnetic permeability that does not depend on the shape. In other words, it is a true magnetic permeability that is not affected by the demagnetic field. The effective magnetic permeability changes because the degree of influence of the demagnetizing field changes when the shape changes. However, the true magnetic permeability is the magnetic permeability from which the influence of the demagnetic field is removed, and can be obtained by forming a completely closed magnetic path and measuring it. For example, if the sample (magnetic wedge) has a ring shape, a completely closed magnetic path is formed, so that the true magnetic permeability can be easily obtained. Even if the sample (magnetic wedge) is not ring-shaped, the true magnetic permeability can be obtained by forming a closed magnetic path using a yoke. FIG. 6 is a schematic view showing a method for measuring the magnetic permeability of the present embodiment. FIG. 6 shows a method of measuring magnetic permeability in three directions. By using a yoke, a closed magnetic path is formed in each of the three directions, and the true magnetic permeability in each of the three directions can be obtained. However, it may be difficult to accurately measure the magnetic permeability in the three directions of the axial magnetic permeability μz, the rotational magnetic permeability μθ, and the radial magnetic permeability μr. In that case, the coercive force may be measured in three directions to estimate the magnetic permeability. In general, the coercive force and the magnetic permeability depend on the magnitude of the magnetic anisotropy. When the magnetic anisotropy is small, the coercive force is also small, and conversely, the magnetic permeability is large. On the contrary, when the magnetic anisotropy is large, the coercive force is also large, and conversely, the magnetic permeability is small. Therefore, the coercive force and the magnetic permeability are correlated through magnetic anisotropy, and the magnitude of the magnetic permeability can be estimated from the value of the coercive force.

However, it should be noted that even if the coercive force is the same, the magnetic permeability may not be the same. For example, even if the coercive force is the same, if the shape of the magnetic material contained in the magnetic wedge has a rod-like shape, the magnetic permeability increases due to the effect of shape magnetic anisotropy in the direction parallel to the rod, and the rod becomes Permeability decreases in the vertical direction. Further, even if the coercive force is the same, if the shape of the magnetic material contained in the magnetic wedge has a flat shape, the magnetic permeability increases due to the effect of the shape magnetic anisotropy in the direction parallel to the flat plane. Permeability decreases in the direction perpendicular to the flat plane. From the above, when determining the relationship between the magnitude of magnetic permeability by the coercive force, first estimate the magnetic permeability based on the magnitude of the coercive force, and then observe the shape of the magnetic material contained in the magnetic wedge. It is also possible to estimate the effect of shape magnetic anisotropy from the shape and to obtain the relationship of the magnitude of magnetic permeability comprehensively.

It is preferable to arrange the magnetic material so that the radial magnetic permeability μr is higher than the rotational magnetic permeability μθ and the axial magnetic permeability μz. This is particularly preferable in the case of a radial gap type rotary electric machine. This effect will be described in detail with reference to FIG. FIG. 7 is a schematic view showing a usage state of the magnetic wedge in the radial gap type rotary electric machine of the present embodiment. For the radial gap type rotary electric machine, the magnetic wedge is mounted so as to bridge between the iron core teeth arranged at predetermined intervals in the rotation direction, and closes the slot opening extending in the axial direction.

Therefore, from the viewpoint of reducing the leakage flux flowing between the iron core teeth via the magnetic wedge, it is preferable that the rotational magnetic permeability μθ is lower than the radial magnetic permeability μr. On the other hand, from the viewpoint of reducing the leakage flux flowing from the void end portion to the outside of the axial core, it is preferable that the axial magnetic permeability μz is lower than the radial magnetic permeability μr.

In summary, it is preferable to arrange the magnetic material so that the radial magnetic permeability μr is higher than the rotational magnetic permeability μθ and the axial magnetic permeability μz, so that the increase in the leakage flux can be minimized. This makes it possible to fully enjoy the effect of improving the efficiency of the rotary electric machine by using the magnetic wedge. More preferably, the magnetic permeability increases in the order of the radial direction, the rotational direction, and the axial direction (radial magnetic permeability μr> rotational magnetic permeability μθ> axial magnetic permeability μz). When the rotational magnetic permeability μθ is larger than the axial magnetic permeability μz, the magnetic flux passing from the iron core tooth to the void side through the wedge increases, and the harmonic loss can be reduced, which is preferable. That is, it is possible to further improve the efficiency of the rotary electric machine by using the magnetic wedge.

In FIG. 7, in the iron core slot, the magnetic wedge fills all the space between the coil and the iron core surface, but it does not necessarily have to fill all. The space occupied by the magnetic wedge may be a part between the coil and the surface of the iron core.

In FIG. 7, a magnetic wedge 100, a coil 230, and an iron core tooth 250 are shown.

It is preferable to arrange the magnetic material so that the axial magnetic permeability μz is higher than the rotational magnetic permeability μθ and the radial magnetic permeability μr. This is particularly preferable in the case of an axial gap type rotary electric machine. This effect will be described in detail with reference to FIG. FIG. 8 is a schematic view showing a usage state of the magnetic wedge in the axial gap type rotary electric machine. For the axial gap type rotary electric machine, the magnetic wedge is mounted so as to bridge between the iron core teeth arranged at predetermined intervals in the rotation direction, and closes the slot opening extending in the radial direction.

In FIG. 8, a magnetic wedge 100, a coil 230, and an iron core tooth 250 are shown.

Therefore, from the viewpoint of reducing the leakage flux flowing between the iron core teeth via the magnetic wedge, it is preferable that the rotational magnetic permeability μθ is lower than the axial magnetic permeability μz. On the other hand, from the viewpoint of reducing the leakage flux flowing from the void end portion to the outside of the radial iron core, it is preferable that the radial magnetic permeability μr is lower than the axial magnetic permeability μz.

In summary, it is preferable to arrange the magnetic material so that the axial magnetic permeability μz is higher than the rotational magnetic permeability μθ and the radial magnetic permeability μr, so that the increase in the leakage flux can be minimized. This makes it possible to fully enjoy the effect of improving the efficiency of the rotary electric machine by using the magnetic wedge. More preferably, the magnetic permeability increases in the order of the axial direction, the rotational direction, and the radial direction (axial magnetic permeability μz> rotational magnetic permeability μθ> radial magnetic permeability μr). When the rotational magnetic permeability μθ is larger than the radial magnetic permeability μr, the magnetic flux passing from the iron core tooth to the void side through the wedge increases, and the harmonic loss can be reduced, which is preferable. That is, it is possible to further improve the efficiency of the rotary electric machine by using the magnetic wedge.

FIG. 9 is a schematic view of a magnetic wedge formed by orienting the magnetic material of the present embodiment. The magnetic material is preferably arranged in an oriented manner. In the present invention, "alignment" means a state in which the main surfaces of the magnetic material are aligned in a specific direction. It is preferable that the average value of the angles formed by the main surface and the reference surface of the magnetic material contained in the magnetic wedge is within the range of ± 20 °. In order to make this configuration easier to understand, FIG. 9A is schematically shown. In FIG. 9A, the normals of the main surfaces of all the magnetic materials included in the magnetic wedge are arranged so as to coincide with a specific direction. Further, FIG. 9B illustrates the angle formed by the main surface and the reference surface of the magnetic material included in the magnetic wedge. Regarding how to determine the reference plane, 10 or more magnetic materials contained in the magnetic wedge are observed with a scanning electron microscope (SEM) or the like, and magnetic materials satisfying substantially perpendicular to the void surface are selected and selected magnetic materials. With respect to the main surface of, the average surface is used as the reference surface. As for the method of determining the reference plane, the measurer may arbitrarily determine the plane as long as it is a plane perpendicular to the void plane. In this case, the angle formed by the reference plane and the main plane, which is arbitrarily determined, is obtained, and it is determined whether or not the degree of variation is within the range of ± 20 °. The magnetic material on the left side of FIG. 9B shows an example when the angle formed by the main surface and the reference surface is 0 °, that is, when the main surface and the reference surface coincide with each other. On the other hand, the magnetic material on the right side shows an example when the angle between the main surface and the reference surface is 20 °. Such a configuration is preferable because a difference in the magnetic permeability of the magnetic wedge is likely to occur (anisotropy becomes large). Further, as shown in FIG. 9C, a magnetic material such as a thin band (ribbon), a thin film, a thick film, or a plate-like member may be used instead of the flat particles.

In FIG. 9, the magnetic wedge 100, the magnetic body 2, the main surface (first surface) 2a, the reference surface RP, and the void surface 240 are shown.

FIG. 10 is a schematic view for explaining an arrangement state of a magnetic material suitable for reducing the leakage flux flowing from the void end portion to the outside of the iron core of the present embodiment. It may be preferable that the main surface of the magnetic material is oriented and arranged along the direction of rotation. This is preferable in the case of both the radial gap type rotary electric machine and the axial gap type rotary electric machine. In order to make this configuration easier to understand, FIG. 10 schematically shows the arrangement state of the magnetic material by taking the case of a radial gap type rotary electric machine as an example. With such a configuration, it is possible to significantly reduce the leakage flux flowing from the void end portion to the outside of the iron core. This makes it possible to fully enjoy the effect of improving the efficiency of the rotary electric machine by using the magnetic wedge.

In FIG. 10, a magnetic wedge 100, a magnetic body 2, a main surface (first surface) 2a, a coil 230, an air gap surface 240, and an iron core tooth 250 are shown.

FIG. 11 is a schematic view for explaining an arrangement state of a magnetic material suitable for reducing the leakage flux flowing through the iron core tooth through the magnetic wedge of the present embodiment. It is preferable that the main surface of the magnetic material is oriented so as to be substantially perpendicular to the rotation direction. This is preferable in the case of both the radial gap type rotary electric machine and the axial gap type rotary electric machine. In order to make this configuration easier to understand, FIG. 11 schematically shows the arrangement state of the magnetic material by taking the case of a radial gap type rotary electric machine as an example. With such a configuration, it is possible to significantly reduce the leakage flux flowing between the iron core teeth via the magnetic wedge. This makes it possible to fully enjoy the effect of improving the efficiency of the rotary electric machine by using the magnetic wedge.

In FIG. 11, a magnetic wedge 100, a magnetic body 2, a main surface (first surface) 2a, a coil 230, an air gap surface 240, and an iron core tooth 250 are shown.

The magnetic material preferably has a difference in magnetic permeability depending on the direction in the main surface. More preferably, the directions in which the magnetic permeability of the magnetic material is highest (the axial direction in which magnetization is easy) are aligned in one direction. Such a configuration is preferable because a difference in the magnetic permeability of the magnetic wedge is likely to occur (anisotropy becomes large). More preferably, the easy axial directions of the magnetic material are aligned in the direction perpendicular to the void surface. That is, in the case of the radial gap type rotary electric machine, it is preferable that the easy axial directions of the magnetic material are aligned in the radial direction, and in the case of the axial gap type rotary electric machine, the easy axial directions of the magnetic material are aligned in the axial direction. Is preferable. With such a configuration, the magnetic permeability of the magnetic wedge tends to have high anisotropy in the direction perpendicular to the void surface and low in the direction parallel to the void surface. This is preferable because the increase in leakage flux due to the use of the magnetic wedge can be suppressed and the effect of improving the efficiency of the rotary electric machine can be fully enjoyed. In addition, the effective magnetic flux (main magnetic flux) can be increased to improve the torque of the rotating electric machine.

FIG. 12 is a conceptual diagram example of a magnetic wedge containing a magnetic material having a magnetic permeability difference depending on the in-plane direction of the present embodiment. FIG. 12 is a diagram illustrating the concept of a magnetic wedge including a magnetic material having a magnetic permeability difference depending on the direction in the main surface, taking the case of a radial gap type rotary electric machine as an example. In the figure, the easy-to-magnetize axis direction of the magnetic material is indicated by the arrow of μe, and the direction perpendicular to the easy-magnetization direction of the magnetic material (that is, the difficult-to-magnetize axis direction of the magnetic material) is indicated by the arrow of μh. FIG. 12 (a) shows a state in which the easy-to-magnetize axial directions of the individual magnetic materials are not aligned (μe> μh, but the directions of μe are not aligned), and FIG. 12 (b) shows the easy-to-magnetize axes of the individual magnetic materials. It shows a state in which the directions are aligned in the direction perpendicular to the void surface (μe> μh, the directions of μe are aligned, and the direction is the direction perpendicular to the void surface).

In FIG. 12, a magnetic wedge 100, a magnetic body 2, a main surface (first surface) 2a, a coil 230, an air gap surface 240, and an iron core tooth 250 are shown.

The magnetic material preferably contains at least one selected from the group consisting of flat particles, ribbons, thin films, thick films and plate-like members. With such a configuration, manufacturing becomes easy, the manufacturing yield is improved, and the manufacturing cost can be reduced. The magnetic material is particularly preferably a thin band (ribbon) or a plate-shaped member. This is because the manufacturing becomes easy, the manufacturing yield is improved, and the manufacturing cost can be particularly reduced.

The magnetic material is particularly preferably flat particles. With such a configuration, it is possible to reduce the eddy current loss generated by the magnetic wedge. This makes it possible to fully enjoy the effect of improving the efficiency of the rotary electric machine by using the magnetic wedge. Further, when a magnetic wedge having a complicated shape is manufactured, since the powder is only solidified, the manufacturing becomes easy, the manufacturing yield is improved, and the manufacturing cost can be reduced.

The magnetic material contains at least one magnetic element selected from the group consisting of iron (Fe), cobalt (Co) and nickel (Ni), has a thickness of 10 nm or more and 100 μm or less, and has an average length in the main surface with respect to the thickness. The ratio is preferably 5 or more and 10000 or less. When the magnetic material is a flat particle, it is a flat particle (flaky particle, flattened particle) having a flat shape (flaky shape, flattened shape).

FIG. 13 is a schematic view of an example of the magnetic material of the present embodiment.

In FIG. 13, the magnetic body 2 and the main surface 2a are shown. In the figure, flat particles are shown as an example, but they may be a thin band (ribbon), a thin film, a thick film, or a plate-shaped member.

The magnetic material contains Fe and Co, and the amount of Co is preferably 10 atomic% or more and 60 atomic% or less, and further preferably 10 atomic% or more and 40 atomic% or less with respect to the total amount of Fe and Co. preferable. This is preferable because magnetic anisotropy is likely to be imparted to a moderately large value. Further, the Fe-Co system is preferable because it is easy to realize high saturation magnetization. Further, when the composition range of Fe and Co falls within the above range, higher saturation magnetization can be realized, which is preferable.

Magnetic materials include Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn and It preferably contains at least one non-magnetic metal selected from the group consisting of rare earth elements. This makes it possible to improve the thermal stability and oxidation resistance of the magnetic material. Among them, Al and Si are particularly preferable because they are easily dissolved in Fe, Co and Ni, which are the main components of the magnetic material, and contribute to the improvement of thermal stability and oxidation resistance.

The thickness of the magnetic material and the ratio of the average length in the main plane to the thickness shall be observed by observing the magnetic material with a transmission electron microscope (TEM) or a scanning electron microscope (SEM). The value obtained by averaging 10 or more values is adopted.

The thickness of the magnetic material is preferably 10 nm or more and 100 μm or less, more preferably 1 μm or more and 100 μm or less. The ratio of the average length in the main surface to the thickness is preferably 5 or more and 10000 or less, and more preferably 10 or more and 1000 or less. When a plurality of magnetic materials are contained in the magnetic wedge, the thickness and the ratio of the average length in the main surface to the thickness are obtained for each magnetic material, and the average value is within the above range. Is preferable. When the thickness is thin and the ratio of the average length in the main surface to the thickness is large, it is preferable from the viewpoint that the eddy current loss can be easily reduced, but on the other hand, the coercive force tends to be slightly large. Therefore, from the viewpoint of reducing the coercive force, it is preferable to have an appropriate thickness and a ratio of the average length in the main surface to the appropriate thickness. In the thickness in the above range and the ratio of the average length in the main surface to the thickness, the material is well-balanced in terms of eddy current loss and low coercive force (low hysteresis loss is possible).

In order to induce magnetic anisotropy, a method of amorphizing the crystallinity of a magnetic material as much as possible and inducing magnetic anisotropy in one direction in the plane by a magnetic field or strain (creating a difference in magnetic permeability). There is also. In this case, it is desirable to make the magnetic material as easily amorphous as possible. From this point of view, the magnetic materials are boron (B), silicon (Si), aluminum (Al), carbon (C), titanium (Ti), zirconium (Zr), hafnium (Hf), niobium (Nb). , Tantal (Ta), molybdenum (Mo), chromium (Cr), copper (Cu), tungsten (W), phosphorus (P), nitrogen (N), gallium (Ga) and yttrium (Y). It is preferable to contain at least one additive element. As a result, amorphization progresses, magnetic anisotropy is easily imparted, and the difference in coercive force in the main surface becomes large, which is preferable. An additive element having a large difference from the atomic radius of at least one first element selected from the group consisting of Fe, Co and Ni is preferable. Further, an additive element such that the mixed enthalpy of at least one first element selected from the group consisting of Fe, Co and Ni and the additive element becomes negatively large is preferable. Further, it is preferable that the system is a multidimensional system composed of a total of three or more kinds of elements including the first element and the additive element. Further, since the additive elements of semimetals such as B and Si have a slow crystallization rate and are easily amorphized, it is advantageous to mix them in the system. From the above viewpoint, B, Si, P, Ti, Zr, Hf, Nb, Y, Cu and the like are preferable, and it is more preferable that the additive element contains any one of B, Si, Zr and Y. preferable. Further, it is preferable that the total amount of the added elements is 0.001 at% or more and 80 at% or less with respect to the total amount of the first element and the added elements. More preferably, it is 5 at% or more and 80 at% or less, and further preferably 10 at% or more and 40 at% or less. It should be noted that the larger the total amount of the added elements, the more amorphization progresses and it becomes easier to impart magnetic anisotropy (that is, it is preferable from the viewpoint of low loss and high magnetic permeability). However, on the other hand, since the proportion of the magnetic metal phase is small, it is not preferable in that the saturation magnetization is small, and it is important to select the composition and the amount of added elements according to the purpose.

The crystal grain size of the magnetic material (the crystal grain size of the main phase containing the magnetic metal) is preferably 10 nm or less. It is more preferably 5 nm or less, still more preferably 2 nm or less. The crystal grain size can be easily obtained from the XRD measurement. That is, the strongest peak among the peaks caused by the magnetic metal phase in XRD can be obtained from the diffraction angle and the half width by Scherrer's equation. Sherrer's equation is represented by D = 0.9λ / (βcosθ), where D is the grain size, λ is the measured X-ray wavelength, β is the full width at half maximum, and θ is the diffraction Bragg angle. The crystal grain size can also be determined by observing a large number of magnetic metal phases with a TEM (Transmission electron microscope, transmission electron microscope) and averaging the grain sizes. When the crystal particle size is small, it is preferable to obtain it by XRD measurement, and when the crystal particle size is large, it is preferable to obtain it by TEM observation. It is preferable to make a comprehensive judgment. The crystal grain size of the magnetic metal phase determined by XRD measurement or TEM observation is preferably 10 nm or less, more preferably 5 nm or less, still more preferably 2 nm or less. As a result, for example, by performing heat treatment in a magnetic field, it becomes easy to impart magnetic anisotropy, and the difference in coercive force in the main surface becomes large, which is preferable. Further, since the small crystal grain size means that the crystal grain size is close to amorphous, the electric resistance is higher than that of the highly crystalline one, which is preferable because the eddy current loss is easily reduced. Further, it is preferable because it is superior in corrosion resistance and oxidation resistance as compared with a highly crystalline one.

The magnetic material preferably contains Fe and Co and has a portion having a body-centered cubic structure (bcc) crystal structure. This is preferable because the magnetic anisotropy is easily imparted to a moderately large value and the above-mentioned magnetic characteristics are improved. Further, even in the case of "a mixed phase crystal structure of bcc and fcc" which partially has a face-centered cubic structure (fcc) crystal structure, magnetic anisotropy is likely to be imparted to a moderately large value, and the above-mentioned magnetic characteristics are improved. It is preferable to do so.

The main surface is preferably crystallinely oriented. The orientation direction is preferably (110) plane orientation or (111) plane orientation, but more preferably (110) plane orientation. When the crystal structure of the magnetic material is a body-centered cubic structure (bcc), (110) plane orientation is preferable, and when the crystal structure of the magnetic material is a face-centered cubic structure (fcc), (111) plane orientation is preferable. This is preferable because the magnetic anisotropy is easily imparted to a moderately large value and the above-mentioned magnetic characteristics are improved.

Further, as a more preferable orientation direction, the (110) [111] direction and the (111) [110] direction are preferable, but the (110) [111] direction is more preferable. When the crystal structure of the magnetic material is a body-centered cubic structure (bcc), the orientation in the (110) [111] direction is preferable, and when the crystal structure of the magnetic material is a face-centered cubic structure (fcc), (111) [110] ] Directional orientation is preferred. This is preferable because the magnetic anisotropy is easily imparted to a moderately large value and the above-mentioned magnetic characteristics are improved. In the present specification, the "(110) [111] direction" means that the slip plane is the (110) plane or a crystallographically equivalent plane, that is, the {110} plane, and the slip direction is the [111] direction or It refers to a crystallographically equivalent direction, that is, the <111> direction. (111) The same applies to the [110] direction. That is, the slip plane is the (111) plane or a plane crystallographically equivalent to it, that is, the {111} plane, and the slip direction is the [110] direction or the direction crystallographically equivalent to it, that is, the <110> direction.

The lattice strain of the magnetic material (lattice strain of the main phase containing the magnetic metal) is preferably 0.01% or more and 10% or less, more preferably 0.01% or more and 5% or less, and further preferably 0.01%. It is preferably 1% or more, more preferably 0.01% or more and 0.5% or less. This is preferable because magnetic anisotropy is likely to be imparted to a moderately large value (difference in magnetic permeability is likely to occur) and magnetic characteristics are improved.

The lattice strain can be calculated by analyzing in detail the line width obtained by the X-ray diffraction method (XRD). That is, by performing the Holder-Wagner plot and the Hall-Williamson plot, the contribution of the line width spread can be separated into the crystal grain size and the lattice strain. This makes it possible to calculate the lattice strain. The Holder-Wagner plot is preferred from the standpoint of reliability. For the Holder-Wagner plot, see, eg, N. et al. C. Halder, C.I. N. J. Wagner, Acta Cryst. 20 (1966) 312-313. Please refer to. Here, the Holder-Wagner plot is expressed by the following equation.

^{That is, β 2} / tan ² θ is plotted on the vertical axis and β / tan θ sin θ is plotted on the horizontal axis, the crystal grain size D is calculated from the slope of the approximate straight line, and the lattice strain ε is calculated from the vertical intercept. The lattice strain (lattice strain (root mean square)) by the Holder-Wagner plot of the above equation is 0.01% or more and 10% or less, more preferably 0.01% or more and 5% or less, and further preferably 0.01% or more 1 % Or less, more preferably 0.01% or more and 0.5% or less, because magnetic anisotropy is likely to be appropriately large and the above-mentioned magnetic characteristics are improved, which is preferable.

The above lattice strain analysis is an effective method when multiple peaks in XRD can be detected, but on the other hand, when the peak intensity in XRD is weak and there are few peaks that can be detected (for example, when only one is detected), analysis is performed. Is difficult. In such a case, it is preferable to calculate the lattice strain by the following procedure. First, the composition was determined by inductively coupled plasma (ICP: Inductively Coupled Plasma) emission spectroscopic analysis, energy dispersive X-ray analysis (EDX: Energy dispersive X-ray Spectrum), etc., and the three compositions of magnetic metal elements Fe, Co, and Ni were obtained. Calculate the ratio (two composition ratios when there are only two magnetic metal elements; one composition ratio (= 100%) when there is only one magnetic metal element). _{Next, the ideal lattice spacing d 0} is calculated from the composition of Fe—Co—Ni (see literature values, etc. In some cases, an alloy having that composition is prepared and the lattice spacing is calculated by measurement). .. After that, the amount of strain can be obtained by finding the difference between the grid plane spacing d of the peaks of the measured sample and the ideal grid plane spacing d _0. That is, in this case, the amount of distortion is _{calculated as (d−d 0} ) / d ₀ × 100 (%). As described above, it is preferable to analyze the lattice strain by using the above-mentioned two methods properly according to the state of the peak intensity, and in some cases, using both of them in combination.

It is preferable that the crystallites of the magnetic material are beaded in one direction in the main plane, or the crystallites are rod-shaped and oriented in one direction in the main plane. This is preferable because the magnetic anisotropy is easily imparted to a moderately large value and the above-mentioned magnetic characteristics are improved.

FIG. 14 is a schematic view showing an example of a magnetic material having a concave portion or a convex portion of the magnetic material of the present embodiment. As shown in FIG. 14, the magnetic material is one of a plurality of concave portions and a plurality of convex portions arranged in the first direction on the main surface, having a length of 1 μm or more, a width of 0.1 μm or more, and an aspect ratio of 2 or more. Or it is preferable to have both. The aspect ratio is defined by the size in the longitudinal direction / the size in the lateral direction. That is, if the length is larger (longer) than the width, the aspect ratio is defined by length / width, and if the width is larger (longer) than the length, the aspect ratio is defined by width / length. To. It is more preferable that the length is larger (longer) than the width because it tends to have uniaxial anisotropy magnetically. Further, the concave portions or the convex portions are arranged in the first direction on the main surface. Here, "arranged in the first direction" means that the longer of the length and width of the concave portion or the convex portion is arranged parallel to the first direction. If the longer of the length and width of the concave portion or the convex portion is arranged within ± 30 degrees from the direction parallel to the first direction, it is considered that the concave portion or the convex portion is "arranged in the first direction". As a result, the magnetic material tends to have uniaxial anisotropy magnetically in the first direction due to the effect of shape magnetic anisotropy (a difference in magnetic permeability tends to occur), which is preferable. From this viewpoint, the width is more preferably 1 μm or more and the length is more preferably 10 μm or more. The aspect ratio is preferably 5 or more, more preferably 10 or more. Further, by providing such a concave portion or a convex portion, the adhesion between the magnetic materials when pulverizing the magnetic material and synthesizing the powder material is improved (anchoring in which the concave portion or the convex portion attaches the particles to each other). This is preferable because it improves mechanical properties such as strength and hardness and thermal stability. When the main surface is inside the magnetic material like a flat spheroid, the length is 1 μm or more and the width is 0.1 μm or more arranged in the first direction on the surface viewed from the direction perpendicular to the main surface. , It is preferable to have one or both of a plurality of concave portions and a plurality of convex portions having an aspect ratio of 2 or more.

In FIG. 14, the magnetic body 2, the main surface 2a, the concave portion 12a, and the convex portion 12b are shown. In the figure, flat particles are shown as an example, but they may be a thin band (ribbon), a thin film, a thick film, or a plate-shaped member.

The magnetic material is selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F), at least a part of the surface of the magnetic material having a thickness of 0.1 nm or more and 1 μm or less. It is preferably covered with a coating layer containing at least one second element.

The coating layer includes Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn and A second second that contains at least one non-magnetic metal selected from the group consisting of rare earth elements and is selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F). It is more preferable to contain an element. As the non-magnetic metal, Al and Si are particularly preferable from the viewpoint of thermal stability. Magnetic materials are Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn and rare earths. When containing at least one non-magnetic metal selected from the group consisting of elements, it is more preferable that the coating layer contains at least one non-magnetic metal which is the same as the non-magnetic metal which is one of the constituents of the magnetic material. Among oxygen (O), carbon (C), nitrogen (N) and fluorine (F), oxygen (O) is preferably contained, and oxides and composite oxides are preferable. The above is from the viewpoint of ease of coating layer formation, oxidation resistance, and thermal stability. As described above, the adhesion between the magnetic material and the coating layer can be improved, and the thermal stability and oxidation resistance of the magnetic wedge can be improved. The coating layer can not only improve the thermal stability and oxidation resistance of the magnetic material, but also improve the electrical resistance of the magnetic material. By increasing the electric resistance, it becomes possible to suppress the eddy current loss and improve the frequency characteristic of the magnetic permeability. Therefore, the coating layer 14 preferably has a high electrical resistance, and preferably has a resistance value of, for example, 1 mΩ · cm or more.

The presence of the coating layer is also preferable from the magnetic point of view. Since the thickness of the magnetic material is smaller than the size of the flat surface, it can be regarded as a pseudo thin film. At this time, the structure in which the coating layer is formed on the surface of the magnetic material and integrated is regarded as a pseudo laminated thin film structure, and the magnetic domain structure is energetically stabilized. This makes it possible to reduce the coercive force (which reduces the hysteresis loss), which is preferable. At this time, the magnetic permeability is also increased, which is preferable. From this point of view, it is more preferable that the coating layer is non-magnetic (the magnetic domain structure is easily stabilized).

From the viewpoint of thermal stability, oxidation resistance, and electrical resistance, the thicker the coating layer, the more preferable it is. However, if the thickness of the coating layer becomes too thick, the saturation magnetization becomes small and the magnetic permeability becomes small, which is not preferable. Also, from a magnetic point of view, if the thickness becomes too thick, the "effect of stabilizing the magnetic domain structure to reduce the coercive force, reduce the loss, and increase the magnetic permeability" is reduced. In consideration of the above, the thickness of the coating layer is preferably 0.1 nm or more and 1 μm or less, and more preferably 0.1 nm or more and 100 m or less.

It is preferable to have an intervening phase between the magnetic materials containing at least one element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F). This is because the electrical resistance of the intervening phase is increased and the eddy current loss of the magnetic wedge can be reduced. From this point of view, it is preferable that the electrical resistance of the intervening phase is higher than that of the magnetic material. Since the intervening phase exists surrounding the magnetic material, it is preferable because it can improve the oxidation resistance and thermal stability of the flat particles. Among these, those containing oxygen are more preferable from the viewpoint of high oxidation resistance and high thermal stability. The intervening phase also plays a role of mechanically adhering the magnetic materials to each other, and is therefore preferable from the viewpoint of high strength. For example, the intervening phase 20 is shown in FIG. 10, but the form of the intervening phase 20 is not limited to this.

In addition, since the intervening phase also plays a role of mechanically adhering magnetic materials to each other, glass fiber, carbon fiber, silicon carbide fiber, boron fiber, alumina fiber, aramid fiber, PBO fiber, polyarylate fiber, polyethylene fiber, It is preferable to mix at least one or more reinforcing materials selected from polyolefin fibers, vinylon fibers, polyester fibers, and nylon fibers.

Further, in the magnetic wedge of the present embodiment, by disposing a non-magnetic material inside the magnetic wedge, the magnetic permeability in the rotation direction is lowered, and the leakage magnetic flux flowing between the iron core teeth via the magnetic wedge is further increased. It can be reduced.

Further, in the magnetic wedge of the present embodiment, the mechanical strength of the magnetic wedge can be further increased by covering the surface of the magnetic wedge with a resin. In this case, the resin is not particularly limited, but is a polyester resin, a polyethylene resin, a polystyrene resin, a polyvinyl chloride resin, a polyvinyl butyral resin, a polyvinyl alcohol resin, a polybutadiene resin, a Teflon (registered trademark) resin, and a polyurethane. Resins, cellulose resins, ABS resins, nitrile-butadiene rubbers, styrene-butadiene rubbers, silicone resins, other synthetic rubbers, natural rubbers, epoxy resins, phenolic resins, allyl resins, polybenzoimidazole resins, amide resins, A polyimide resin, a polyamideimide resin, or a copolymer thereof is used. In particular, it is preferable to contain a silicone resin or a polyimide resin having high heat resistance.

Next, the effect of this embodiment will be described.

Here, as an example, Table 1 shows the results of the electromagnetic field numerical analysis by the finite element method for the radial gap type rotary electric machine. An embodiment is a magnetic wedge formed by arranging the main surface of a magnetic material perpendicular to the axial direction of a rotating electric machine and having a difference in magnetic permeability depending on the direction in the main surface of the magnetic material. That is, there is a difference in the magnetic permeability in the three directions of the axial magnetic permeability μz, the rotational magnetic permeability μθ, and the radial magnetic permeability μr, and the magnetic permeability increases in the order of the radial direction, the rotational direction, and the axial direction ( The radial magnetic permeability μr> the rotational magnetic permeability μθ> the axial magnetic permeability μz).

On the other hand, a comparative example is a magnetic wedge formed by arranging the main surface of a magnetic material perpendicular to the axial direction of a rotary electric machine and having the same magnetic permeability in all directions in the main surface. That is, it is not possible to impart a difference in magnetic permeability in the two directions of the rotation direction and the radial direction (radial magnetic permeability μr = rotational magnetic permeability μθ> axial magnetic permeability μz).

By comparing the examples and the comparative examples, in the magnetic wedge formed by arranging the main surface of the magnetic material perpendicular to the axial direction of the rotating electric machine, magnetic anisotropy is imparted to the main surface of the magnetic material and the rotation direction is applied. It is possible to verify the effect when the magnetic permeability μθ is lower than the radial magnetic permeability μr.

As is clear from the analysis results in Table 1, the magnetic wedge of the example has a lower magnetic permeability μθ in the rotational direction than the magnetic wedge of the comparative example, so that the ratio of the leakage magnetic flux can be reduced, which improves the efficiency of the rotating electric machine. It turns out that it is a suitable magnetic wedge. Further, in this analysis, it is confirmed that the loss reduction due to the pulsation relaxation of the void magnetic flux distribution and the torque increase due to the increase in the effective magnetic flux contribute to the improvement of the efficiency of the rotating electric machine, but only one of them may be used. Absent.

Here, in a magnetic wedge formed by laminating magnetic materials in the axial direction, when magnetic anisotropy is imparted in the main surface of the magnetic material to make the rotational magnetic permeability μθ lower than the radial magnetic permeability μr. Although the effect was shown, in a magnetic wedge formed by arranging the main surface of the magnetic material perpendicular to the rotation direction of the rotating electric machine, magnetic anisotropy is imparted to the main surface of the magnetic material to increase the axial magnetic permeability μz. The effect when it is lower than the directional magnetic permeability μr, that is, when the radial magnetic permeability μr> the axial magnetic permeability μz> the rotational magnetic permeability μθ, and the radial magnetic permeability μr = the axial magnetic permeability μz> the rotational magnetic permeability The difference in effect) in the case of magnetic permeability μθ can also be confirmed in the same manner.

The effect of the magnetic wedge of the present embodiment can be similarly confirmed for the axial rotary electric machine.

According to the magnetic wedge of the present embodiment, the increase of the leakage flux is minimized, the magnetic wedge capable of effectively relaxing the pulsation of the magnetic flux distribution on the surface of the iron core is provided, and the efficiency of the rotary electric machine is improved. Is possible. In some cases, the effective magnetic flux (main magnetic flux) can be increased, and the torque of the rotating electric machine can also be improved. Further, by forming the magnetic wedge using a magnetic material having a main surface, the control range of the magnetic permeability in three directions can be increased, and the efficiency of the rotary electric machine can be improved. In addition, manufacturing becomes easy, manufacturing yield is improved, and manufacturing cost can be reduced.

(Second embodiment)
The rotary electric machine of the present embodiment is characterized by including the magnetic wedge of the first embodiment. Therefore, the description of the contents overlapping with the first embodiment will be omitted. In the present specification, the rotary electric machine means a concept including any of an electric motor (motor), a generator (generator), and, if necessary, a motor / generator that functions as both a motor and a generator.

In the radial gap type motor of the present embodiment, the magnetic material having the main surface is arranged so that the main surface is substantially perpendicular to the void surface, and there are three directions of axial magnetic permeability, rotational magnetic permeability, and radial magnetic permeability. It is characterized by having a magnetic wedge having a difference in magnetic permeability.

FIG. 15 is a schematic view showing an example of the radial gap type rotary electric machine of the present embodiment. FIG. 15 is an example of the radial gap type motor of this embodiment. The radial gap type rotary electric machine has a rotor and a stator arranged so as to face the rotor with a predetermined gap in the radial direction. In FIG. 15, the rotor is arranged inside the stator, but it may be arranged outside. The rotor has a rotor core and a shaft and is supported so that it can rotate. On the other hand, the stator includes a stator core, a field coil inserted in the slot of the stator core, and a magnetic wedge held in a wedge groove at the slot opening. FIG. 15 shows, as an example, a case where the magnetic wedge is arranged so that the radial magnetic permeability μr is higher than the rotational magnetic permeability μθ and the axial magnetic permeability μz, but the present invention is not limited to this.

In this way, the magnetic wedge has a difference in magnetic permeability in the three directions of axial magnetic permeability μz, rotational magnetic permeability μθ, and radial magnetic permeability μr, so that the increase in leakage magnetic flux can be suppressed and the rotor surface can be pressed. It is possible to reduce the generated harmonic loss. Further, since the magnetic flux passing through the gap increases, the torque of the radial gap type motor is increased. High efficiency can be achieved by either or both of the above loss reduction effect and torque increase effect.

In the figure, flat particles are used, but a thin band (ribbon), a thin film, a thick film, or a magnetic material of a plate-like member may be used.

As the material of the iron core, any of a laminated core of magnetic thin plates, a dust core obtained by compression molding magnetic particles, a ferrite core and the like may be adopted.

In particular, in a radial gap type motor that employs a laminated core of magnetic thin plates, eddy current loss occurs when the main surface of the magnetic material contained in the magnetic wedge and the main surface of the magnetic thin plate forming the laminated core are arranged in parallel. Is particularly preferable because it can reduce the amount of

The radial gap type motor may be a rotor equipped with a conductor (induction motor), a permanent magnet (permanent magnet motor), or a magnetic material (reluctance motor). I do not care.

In the axial gap type motor of the present embodiment, the magnetic material having the main surface is arranged so that the main surface is substantially perpendicular to the void surface, and the axial magnetic permeability, the rotational magnetic permeability, and the radial magnetic permeability are three directions. It is characterized by having a magnetic wedge having a difference in magnetic permeability.

FIG. 16 is a schematic view showing an example of the axial gap type rotary electric machine of the present embodiment. FIG. 16 is an example of the axial gap type motor of this embodiment. The axial gap type motor has a rotor and a stator that are arranged so as to face the rotor with a predetermined gap in the axial direction, and in the stator, in the stator core, and in the slots of the stator core. It includes an inserted field coil and a magnetic wedge held in the wedge groove of the slot opening. FIG. 16 shows, as an example, a case where the magnetic wedge is arranged so that the axial magnetic permeability μz is higher than the radial magnetic permeability μr and the rotational magnetic permeability μθ, but the present invention is not limited to this. In this way, the magnetic wedge has a difference in magnetic permeability in the three directions of axial magnetic permeability μz, rotational magnetic permeability μθ, and radial magnetic permeability μr, so that the increase in leakage magnetic flux can be suppressed and the rotor surface can be pressed. It is possible to reduce the generated harmonic loss. Further, since the magnetic flux passing through the gap increases, the torque of the axial gap type motor is increased. As a result, high efficiency can be realized.

In FIG. 16, the rotor is arranged between the two stators, but it may be arranged on one side or both sides of one stator.

Although flat particles are used in FIG. 16, magnetic materials such as a thin band (ribbon), a thin film, a thick film, and a plate-like member may be used.

As the material of the iron core, any of a laminated core of magnetic thin plates, a dust core obtained by compression molding magnetic particles, a ferrite core, and the like may be adopted. In particular, in an axial gap type motor that employs a laminated core of magnetic thin plates, eddy current loss occurs when the main surface of the magnetic material contained in the magnetic wedge and the main surface of the magnetic thin plate forming the laminated core are arranged in parallel. Is particularly preferable because it can reduce the amount of

In the generator of the present embodiment, the magnetic material having the main surface is arranged so that the main surface is substantially perpendicular to the void surface, and the magnetic permeability is given a difference in the three directions of the axial direction, the rotation direction, and the radial direction. It is characterized by having a magnetic wedge.

FIG. 17 is a schematic view showing an example of the generator of the present embodiment. The generator usually has a rotor that houses the exciting coil in the slot of the rotor core (in addition, a rotor that uses a permanent magnet as the excitation source may be adopted) and an armature coil in the slot of the stator core. By having a stator that houses the stator, rotating the rotor, and passing an exciting current through the exciting coil, power is generated in the armature coil. The rotor includes a rotor core, a field coil inserted in the slot of the rotor core, and a magnetic wedge held in a wedge groove at the slot opening, and is supported so as to be rotatable by a bearing. FIG. 17 shows, as an example, a case where the magnetic wedge is arranged so that the radial magnetic permeability μr is higher than the rotational magnetic permeability μθ and the axial magnetic permeability μz, but the present invention is not limited to this.

In this way, in the magnetic wedge, by having a difference in magnetic permeability in three directions of axial magnetic permeability μz, rotational magnetic permeability μθ, and radial magnetic permeability μr, the increase in leakage magnetic flux is suppressed and the stator surface is formed. It is possible to reduce the generated harmonic loss. Further, since the magnetic flux passing through the gap and interlinking with the armature coil increases, the generated voltage induced in the armature coil increases. As a result, high efficiency can be realized.

In FIG. 17, the magnetic wedge is arranged in the slot opening of the rotor core, but it may be arranged in the slot opening of the stator core. Further, in the figure, a winding type generator in which the rotor is provided with an exciting coil is shown, but a permanent magnet type generator in which the rotor is provided with a permanent magnet may be used. In this case, the magnetic wedge is placed in the slot opening of the stator core.

In FIG. 17, flat particles are used, but a thin band (ribbon), a thin film, a thick film, or a magnetic material of a plate-like member may be used.

As the material of the iron core, any of a laminated core of magnetic thin plates, a dust core obtained by compression molding magnetic particles, a ferrite core and the like may be adopted. In particular, in a generator using a laminated core of magnetic thin plates, eddy current loss is reduced when the main surface of the magnetic material contained in the magnetic wedge and the main surface of the magnetic thin plates forming the laminated core are arranged in parallel. It is particularly preferable because it can be used.

Since the linear motor is a developed radial gap type motor and has a flat plate-like structure, the magnetic wedge of the present invention can be applied to the linear motor. That is, the stator may include a stator core and a field coil inserted in the slot of the stator core, and a magnetic wedge may be provided at the slot opening. FIG. 18 is a schematic view showing an example of the linear motor of the present embodiment. In a linear motor, the traveling direction of the mover, the direction perpendicular to the traveling direction of the mover, and the direction perpendicular to the stator correspond to the rotational direction, the axial direction, and the radial direction of the radial gap type motor, respectively.

At this time, as shown in FIG. 18, the magnetic characteristics of the magnetic wedge are as follows: in the magnetic wedge, the magnetic permeability μz in the direction perpendicular to the stator, the magnetic permeability μx in the moving direction of the mover, and the direction perpendicular to the traveling direction. It is preferable to give a difference to the magnetic permeability in the three directions of the magnetic permeability μy. In FIG. 18, the magnetic permeability μz in the direction perpendicular to the stator is arranged to be higher than the magnetic permeability μx in the traveling direction of the mover and the magnetic permeability μy in the direction perpendicular to the traveling direction, but the present invention is limited to this. Not done. This makes it possible to reduce the harmonic loss generated on the surface of the mover while suppressing the increase in the leakage flux. Further, since the magnetic flux passing through the gap increases, the thrust of the linear motor is improved. As a result, high efficiency can be realized. FIG. 18 shows the mover 290.

In FIG. 18, flat particles are used, but a thin band (ribbon), a thin film, a thick film, or a magnetic material of a plate-like member may be used.

According to the rotary electric machine of the present embodiment, the increase of the leakage flux due to the use of the magnetic wedge can be suppressed, and the pulsation of the magnetic flux distribution on the surface of the iron core can be effectively alleviated, so that high efficiency can be realized.

The slot shape of the rotary electric machine of the present embodiment may be a semi-closed slot (or a semi-closed slot), but is preferably an open slot (or an open slot or an open slot). At this time, harmonic loss can be significantly reduced, which is preferable.

The rotary electric machine of the present embodiment includes transportation systems such as railroads, electric vehicles and hybrid cars, social systems such as elevators and air conditioners, industrial systems such as robots, pumps, compressors and blowers, thermal power generators and hydraulic power generators. It can be applied to energy systems such as wind power generators, nuclear power generators, and geothermal power generators, and home appliances such as washing machines, and can improve the efficiency of the systems. In particular, in a large-capacity machine for industrial use, since an open slot is generally adopted in the slot shape, it is preferable to provide the magnetic wedge of the first embodiment. Further, in the traction motor for railways, a type-wound coil is used because it is necessary to withstand high voltage and vibration, and an open slot is adopted in the slot shape. Therefore, the magnetic wedge of the first embodiment may be provided. preferable.

In particular, in railways, the loss of the rotating electric machine accounts for about half of the power consumption during railway running, so the effect of improving efficiency by reducing the loss of the rotating electric machine is great. Further, in an electric vehicle or a hybrid vehicle, the efficiency of the traction motor can be improved by using the magnetic wedge of the first embodiment, so that the cruising range can be extended.

Although some embodiments and examples of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments and examples can be implemented in various other embodiments, and various omissions, replacements, and changes can be made without departing from the gist of the invention. These embodiments, examples and modifications thereof are included in the scope and gist of the invention, and are also included in the scope of the invention described in the claims and the equivalent scope thereof.

2 Magnetic material 2a First surface 2b Second surface 12a Concave part 12b Convex part 20 Intervening phase 100 Magnetic wedge 200 Rotating electric machine 200a Radial gap type rotating electric machine 200b Axial gap type rotating electric machine 210 Rotor 220 Stator core 230 Coil 240 Air gap Surface 250 Iron core teeth 260 Iron core slot 270 Stator 280 Shaft 290 Rotor RP reference surface

Claims (5)

A magnetic wedge used in a radial gap type rotary electric machine in which stators are arranged facing each other at predetermined intervals in the radial direction with respect to the rotor.
The magnetic wedge has a main surface, has a thickness of 10 nm or more and 100 μm or less, and the ratio of the average length in the main surface to the thickness is 5 or more and 10000 or less, and iron (Fe) and cobalt (Co). And flat particles of planar structure containing at least one magnetic element selected from the group consisting of nickel (Ni).
The main surface is oriented along the rotation direction of the rotary electric machine and is arranged substantially perpendicular to the gap surface between the stator and the rotor.
A magnetic wedge in which the radial coercive force in the radial direction of the rotary electric machine is lower than the rotational coercive force in the rotational direction of the rotary electric machine, and the rotational coercive force is lower than the axial coercive force in the axial direction of the rotary electric machine. A magnetic wedge used in a radial gap type rotary electric machine in which stators are arranged facing each other at predetermined intervals in the radial direction with respect to the rotor.
The magnetic wedge has a main surface, has a thickness of 10 nm or more and 100 μm or less, and the ratio of the average length in the main surface to the thickness is 5 or more and 10000 or less, and iron (Fe) and cobalt (Co). And flat particles of planar structure containing at least one magnetic element selected from the group consisting of nickel (Ni).
The main surface is oriented substantially perpendicular to the rotation direction of the rotary electric machine, and is arranged substantially perpendicular to the gap surface between the stator and the rotor.
A magnetic wedge whose radial coercive force in the radial direction of the rotary electric machine is lower than the axial coercive force in the axial direction of the rotary electric machine and whose axial coercive force is lower than the rotational coercive force in the rotational direction of the rotary electric machine. A magnetic wedge used in an axial gap type rotary electric machine in which stators are arranged facing the rotor at predetermined intervals in the axial direction.
The magnetic wedge has a main surface, has a thickness of 10 nm or more and 100 μm or less, and the ratio of the average length in the main surface to the thickness is 5 or more and 10000 or less, and iron (Fe) and cobalt (Co). And flat particles of planar structure containing at least one magnetic element selected from the group consisting of nickel (Ni).
The main surface is oriented along the rotation direction of the rotary electric machine and is arranged substantially perpendicular to the gap surface between the stator and the rotor.
A magnetic wedge whose axial coercive force in the axial direction of the rotary electric machine is lower than the rotational coercive force in the rotational direction of the rotary electric machine and whose rotational coercive force is lower than the radial coercive force in the radial direction of the rotary electric machine. .. A magnetic wedge used in an axial gap type rotary electric machine in which stators are arranged facing the rotor at predetermined intervals in the axial direction.
The magnetic wedge has a main surface, has a thickness of 10 nm or more and 100 μm or less, and the ratio of the average length in the main surface to the thickness is 5 or more and 10000 or less, and iron (Fe) and cobalt (Co). And flat particles of planar structure containing at least one magnetic element selected from the group consisting of nickel (Ni).
The main surface is oriented substantially perpendicular to the rotation direction of the rotary electric machine, and is arranged substantially perpendicular to the gap surface between the stator and the rotor.
A magnetic wedge whose axial coercive force in the axial direction of the rotary electric machine is lower than the radial coercive force in the radial direction of the rotary electric machine and whose radial coercive force is lower than the rotational coercive force in the rotational direction of the rotary electric machine. .. A rotary electric machine provided with the magnetic wedge according to any one of claims 1 to 4.

Images