JP2023136154A - Rotary electric machine and manufacturing method of rotary electric machine - Google Patents

Abstract

To provide a rotary electric machine which can easily be assembled, and a manufacturing method of the rotary electric machine.SOLUTION: A magnet unit 22 of a rotary electric machine 10 includes: a plurality of magnets 32 arranged side by side in a circumferential direction; and a magnetic holder 31 to which the plurality of magnets 32 are fixed. The magnet 32 is oriented such that a direction of a magnetization easy axis is parallel to a d-axis compared to a q-axis side being a magnetic pole boundary on the d-axis side which is a magnetic pole center, and a magnet path is formed along the magnetization easy axis. The magnet holder 31 is formed in a cylindrical shape and is fixed through an adhesive 37 in a state in which the plurality of magnets 32 are arranged side by side in the circumferential direction on a magnet holding face. The magnets 32 are divided in the d-axis and the q-axis. Each magnet 32 is arranged so that a gap 39 between magnets is formed on the d-axis side, and side faces of the q-axis side abut each other. The gap 39 between magnets of the magnets 32 adjacent in the circumferential direction on the d-axis is filled with a resin member 38.SELECTED DRAWING: Figure 7

Description

The present invention relates to a rotating electric machine.

BACKGROUND ART Conventionally, in order to improve the output torque of a rotating electrical machine, a technique has been proposed in which a sintered magnet with a modified orientation direction of an axis of easy magnetization is used to improve the maximum magnetic flux density (for example, Patent Document 1).

JP 2021-40405 Publication

Generally, the above-mentioned magnets are manufactured by manufacturing a plurality of magnets and arranged in an annular shape along the circumferential direction of the rotating shaft. By the way, when manufacturing a magnet in which the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary, the d-axis and q Orientation and magnetization can be more easily achieved by dividing the magnets along the axis than by dividing them between the d-axes (or between the q-axes) adjacent in the circumferential direction. In other words, it is easier to manufacture a magnet that has one magnetic pole on the stator side magnet surface than to manufacture a magnet that has different magnetic poles on the stator side magnet surface, and it is also easier to increase the magnetic force. It has become.

However, in the case of employing magnets separated along the d-axis, when the magnets are arranged in an annular shape after being magnetized, they have the same polarity on the d-axis and repel each other. For this reason, there was a problem in that it became difficult to assemble.

The present invention has been made in view of the above circumstances, and its main purpose is to provide a rotating electrical machine that can be easily assembled and a method for manufacturing the rotating electrical machine.

A first means for solving the above problem includes a field element having a magnet portion including a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature having a multiphase armature winding. , in a rotating electrical machine in which one of the field element and the armature is a rotor, the magnet section includes a plurality of magnets arranged in a circumferential direction, and a magnet holder to which the plurality of magnets are fixed. The magnet is oriented such that the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary, and the magnet is magnetized. A magnet magnetic path is formed along the easy axis, and the magnet holding section is fixed to its magnet holding surface with an adhesive in a state in which a plurality of the magnets are arranged side by side in the circumferential direction. are separated at least along the d-axis, and a gap between the circumferentially adjacent magnets on the d-axis is filled with a resin member.

As a result, since a gap is formed in the d-axis, it becomes easier to fix the magnet to the magnet holder. Further, by filling the gap between the d-axis side side surfaces of the magnets with a resin member, the gap between the magnets is eliminated, and positional displacement in the circumferential direction can be prevented.

A second means for solving the above problem includes a field element having a magnet portion including a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature having a multiphase armature winding. , in the method for manufacturing a rotating electrical machine in which one of the field element and the armature is used as a rotor, the magnet portion includes a plurality of magnets arranged side by side in a circumferential direction, and a plurality of magnets fixed to each other. The magnet is divided along the d-axis, and the axis of easy magnetization is oriented in a direction on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary. The magnet is oriented parallel to the d-axis, and a magnet magnetic path is formed along the axis of easy magnetization. a first fixing step of arranging the magnets every other time and fixing them with an adhesive so that a gap corresponding to the size is formed; and a predetermined inter-magnet gap between the d-axes of circumferentially adjacent magnets. a second fixing step of arranging the magnets in the gaps between the magnets formed in the first fixing step and fixing them to the magnet holding surface of the magnet holding part with an adhesive so that the magnets are formed; The second fixing step includes a filling step of filling the predetermined gap between the magnets with resin.

As a result, a gap between the magnets is formed on the d-axis, so that the magnet can be easily fixed to the magnet holder. Further, by filling the gap between the magnets between the side surfaces of the magnets on the d-axis side with resin, the gap between the magnets is eliminated, and positional displacement in the circumferential direction can be prevented. Further, in the first fixing step, since every other magnet is fixed, it is easier to fix the magnets than when all the magnets are fixed at the same time.

A third means for solving the above problem includes a field element having a magnet portion including a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature having a multiphase armature winding. , in the method for manufacturing a rotating electrical machine in which one of the field element and the armature is used as a rotor, the magnet portion includes a plurality of magnets arranged side by side in a circumferential direction, and a plurality of magnets fixed to each other. The magnet is divided along the d-axis and the q-axis, and has an axis of easier magnetization on the d-axis side, which is the magnetic pole center, than on the q-axis side, which is the magnetic pole boundary. is oriented so that the direction thereof is parallel to the d-axis, and a magnet magnetic path is formed along the axis of easy magnetization, and the q-axis side end surfaces of the magnets are attracted to each other by magnetic force to form a magnet combination. step, attaching every other magnet to the magnet holding surface of the magnet holding part so that a gap corresponding to the circumferential dimension of the magnet combination is formed along the circumferential direction of the magnet combination. a first fixing step in which the magnets are arranged and fixed with adhesive; and each magnet formed in the first fixing step so that a predetermined inter-magnet gap is formed between the d axes of circumferentially adjacent magnets. a second fixing step of arranging the magnet bonds in the gaps between the bonds and fixing them to the magnet holding surface of the magnet holding part with an adhesive; and a predetermined gap between the magnets formed in the second fixing step. and a filling step of filling the gap with resin.

As a result, since a gap is formed in the d-axis, it becomes easier to fix the magnet to the magnet holder. Further, by filling the gap between the magnets between the side surfaces of the magnets on the d-axis side with resin, the gap between the magnets is eliminated, and positional displacement in the circumferential direction can be prevented. Further, in the first fixing step, since every other magnet assembly is fixed, it is easier to fix the magnet assembly than when all the magnet assembly are fixed at once.

FIG. 1 is a perspective view showing the entire rotating electrical machine in the first embodiment. A plan view of a rotating electric machine. A vertical cross-sectional view of a rotating electric machine. A cross-sectional view of a rotating electric machine. An exploded cross-sectional view of a rotating electric machine. A cross-sectional view of the rotor. FIG. 3 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit. 1 is a flowchart showing the flow of a method for manufacturing a magnet unit. FIG. 3 is a cross-sectional view showing the manufacturing process of the magnet unit. FIG. 7 is a perspective cross-sectional view showing a rotor carrier of a modified example. FIG. 3 is a perspective view showing a ring member. FIG. 3 is a perspective sectional view showing a ring member. (a) is a longitudinal end view showing a rotor carrier of a modified example, and (b) is a perspective view schematically showing a protrusion. FIG. 7 is a cross-sectional view showing a modified example of a magnet.

The rotating electrical machine in this embodiment is used, for example, as a vehicle power source. However, rotating electric machines can be widely used for industrial purposes, vehicles, aircraft, home appliances, OA equipment, game machines, and the like. Note that in each of the following embodiments, parts that are the same or equivalent to each other are denoted by the same reference numerals in the drawings, and the explanations thereof will be referred to for the parts with the same reference numerals.

(First embodiment)
The rotating electric machine 10 according to the present embodiment is a synchronous multiphase AC motor, and has an outer rotor structure (external rotation structure). An outline of the rotating electric machine 10 is shown in FIGS. 1 to 5. 1 is a perspective view showing the entire rotating electrical machine 10, FIG. 2 is a plan view of the rotating electrical machine 10, and FIG. 3 is a longitudinal sectional view of the rotating electrical machine 10 (a sectional view taken along line 3-3 in FIG. ), and FIG. 4 is a cross-sectional view (cross-sectional view taken along the line 4--4 in FIG. 3) of the rotating electrical machine 10, and FIG. 5 is an exploded sectional view showing the components of the rotating electrical machine 10 in an exploded manner. In the following description, in the rotating electrical machine 10, the direction in which the rotating shaft 11 extends is referred to as the axial direction, the direction extending radially from the center of the rotating shaft 11 is referred to as the radial direction, and the direction extending circumferentially around the rotating shaft 11 as the center is referred to as the circumferential direction. direction.

The rotating electrical machine 10 is roughly divided into a rotating electrical machine main body having a rotor 20, a stator unit 50, and a busbar module 200, and a housing 241 and a housing cover 242 provided so as to surround the rotating electrical machine main body. All of these members are arranged coaxially with respect to the rotating shaft 11 that is integrally provided to the rotor 20, and are assembled in the axial direction in a predetermined order to configure the rotating electrical machine 10. The rotating shaft 11 is supported by a pair of bearings 12 and 13 provided in the stator unit 50 and the housing 241, respectively, and is rotatable in this state. Note that the bearings 12 and 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged between them. The rotation of the rotating shaft 11 causes, for example, the axle of the vehicle to rotate. The rotating electrical machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle body frame or the like.

In the rotating electric machine 10, the stator unit 50 is provided so as to surround the rotating shaft 11, and the rotor 20 is arranged on the radially outer side of the stator unit 50. The stator unit 50 includes a stator 60 and a stator holder 70 assembled inside the stator 60 in the radial direction. The rotor 20 and the stator 60 are arranged to face each other in the radial direction with an air gap in between, and as the rotor 20 rotates together with the rotating shaft 11, the rotor 20 rotates on the outside of the stator 60 in the radial direction. Rotate. The rotor 20 corresponds to a "field element" and the stator 60 corresponds to an "armature."

The stator 60 has a stator winding 61 and a stator core 62. Note that the stator winding 61 corresponds to the "armature winding". In this embodiment, the stator 60 has a slotless structure that does not have teeth for forming slots, but teeth may be provided.

FIG. 6 is a longitudinal cross-sectional view of the rotor 20. As shown in FIG. 6, the rotor 20 includes a substantially cylindrical rotor carrier 21 and an annular magnet unit 22 fixed to the rotor carrier 21. As shown in FIG. The rotor carrier 21 has a cylindrical portion 23 having a cylindrical shape and an end plate portion 24 provided at one end in the axial direction of the cylindrical portion 23, and is configured by integrating these parts. . In the rotor carrier 21, a magnet unit 22 is fixed to the radially inner side of the cylindrical portion 23 in an annular shape. A through hole 24a is formed in the end plate portion 24, and the rotating shaft 11 is fixed to the end plate portion 24 by a fastener 25 such as a bolt while being inserted into the through hole 24a. The rotating shaft 11 has a flange 11a extending in a direction intersecting (orthogonal to) the axial direction, and the rotor carrier 21 is attached to the rotating shaft 11 in a state where the flange 11a and the end plate portion 24 are surface-joined. is fixed.

The magnet unit 22 includes a cylindrical magnet holder 31, a plurality of magnets 32 fixed to the inner circumferential surface of the magnet holder 31, and a magnet holder 31 on the opposite side from the end plate portion 24 of the rotor carrier 21 on both sides in the axial direction. It has a fixed end plate 33. In this embodiment, the magnet holder 31 corresponds to a "magnet holding part", and the inner peripheral surface of the magnet holder 31 corresponds to a "magnet holding surface". The end plate 33 is formed in an annular shape and is configured to cover part or all of the axial end surface of the magnet 32 to prevent the magnet 32 from falling off. Each magnet 32 is fixed to the inner peripheral surface of the magnet holder 31 with an adhesive 37.

The magnet holder 31 has the same length dimension as the magnet 32 in the axial direction. The magnet 32 is surrounded by the magnet holder 31 from the outside in the radial direction. The magnet holder 31 and the magnet 32 are fixed in contact with an end plate 33 at one end in the axial direction. The magnet unit 22 corresponds to a "magnet section".

FIG. 7 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 22. As shown in FIG. In FIG. 7, the direction of the axis of easy magnetization of the magnet 32 is indicated by an arrow.

In the magnet unit 22, the magnets 32 are arranged in parallel along the circumferential direction of the rotor 20 so that their polarities alternate. Thereby, the magnet unit 22 has a plurality of magnetic poles in the circumferential direction. The magnet 32 is a polar anisotropic permanent magnet, using a sintered neodymium magnet having an intrinsic coercive force of 400 [kA/m] or more and a residual magnetic flux density Br of 1.0 [T] or more. It is configured.

The radially inner circumferential surface (on the stator 60 side) of the magnet 32 is a magnetic flux acting surface 34 where magnetic flux is transferred. The magnet unit 22 is configured to generate magnetic flux intensively in a region near the d-axis, which is the center of the magnetic pole, on the magnetic flux acting surface 34 of the magnet 32. Specifically, in the magnet 32, the direction of the axis of easy magnetization is different between the d-axis side (portion closer to the d-axis) and the q-axis side (portion closer to the q-axis). is parallel to the d-axis, and on the q-axis side, the axis of easy magnetization is perpendicular to the q-axis. In this case, an arcuate magnet magnetic path is formed along the direction of the axis of easy magnetization. In short, the magnet 32 is configured such that the axis of easy magnetization is more parallel to the d-axis on the d-axis side, which is the magnetic pole center, than on the q-axis side, which is the magnetic pole boundary.

In the magnet 32, the magnet magnetic path is formed in an arc shape, so that the length of the magnet magnetic path is longer than the thickness dimension of the magnet 32 in the radial direction. This increases the permeance of the magnet 32, making it possible to exhibit the same ability as a magnet with a larger amount of magnets, even though the amount of magnets is the same.

The magnets 32 are configured such that two circumferentially adjacent magnets constitute one magnetic pole. In other words, the plurality of magnets 32 arranged in the circumferential direction in the magnet unit 22 each have a split surface on the d-axis and the q-axis, and the magnets 32 are arranged in contact with or close to each other. . More specifically, each magnet 32 is arranged so that the d-axis side surfaces are slightly separated from each other on the d-axis side, and is arranged so that the q-axis side surfaces are in contact with each other on the q-axis side. ing.

The magnets 32 have an arc-shaped magnet magnetic path as described above, and the N and S poles of magnets 32 adjacent to each other in the circumferential direction face each other on the q-axis. Therefore, permeance near the q-axis can be improved. Furthermore, since the magnets 32 on both sides of the q-axis attract each other, these magnets 32 can maintain contact with each other. Therefore, it also contributes to improving permeance.

In the magnet unit 22, magnetic flux flows in an arc shape between adjacent N and S poles of each magnet 32, so the magnet magnetic path is longer than, for example, a radial anisotropic magnet. Therefore, the magnetic flux density distribution becomes close to a sine wave. As a result, unlike the magnetic flux density distribution of a radial anisotropic magnet, the magnetic flux can be concentrated on the center side of the magnetic pole, making it possible to increase the torque of the rotating electric machine 10. That is, according to each of the magnets 32 having the above configuration, the magnet magnetic flux on the d-axis in the magnet unit 22 is strengthened, and changes in the magnetic flux near the q-axis are suppressed. Thereby, it is possible to suitably realize the magnet unit 22 in which the surface magnetic flux changes gradually from the q-axis to the d-axis in each magnetic pole.

The magnet 32 has a recess 35 formed on its radially outer peripheral surface in a predetermined range including the d-axis. In other words, on the d-axis side, the corners on the outer peripheral surface of each magnet 32 are chamfered, and on the d-axis side, the d-axis side side surfaces of each magnet 32 are close to each other, so that a groove-shaped groove is formed along the axial direction. A recess 35 will be formed.

In this case, according to the orientation of the axis of easy magnetization of the magnet 32, the magnet magnetic path becomes shorter near the d-axis on the outer peripheral surface of the magnet 32. Therefore, in consideration of the fact that it is difficult to generate sufficient magnetic flux in the magnet 32 at a location where the magnet magnetic path length is short, the magnet is removed at a location where the magnet magnetic flux is weak.

The gap formed between the recess 35 and the d-axis side side surface of the magnet 32 (hereinafter referred to as an inter-magnet gap 39) is filled with resin to form a resin member 38. That is, the recess 35 and the inter-magnet gap 39 are filled with the resin member 38. This resin member 38 has a certain degree of elasticity and prevents the magnet 32 from shifting in the circumferential direction.

The magnet 32 has a concave portion 36 formed in a predetermined range including the q-axis on the radially inner inner circumferential surface (magnetic flux acting surface 34). In other words, on the q-axis side, the corners on the inner circumferential surface of each magnet 32 are chamfered, and on the q-axis side, the q-axis side surfaces of each magnet 32 come into contact with each other, so that a groove-like shape is formed along the axial direction. A recess 36 is formed.

In this case, according to the orientation of the axis of easy magnetization of the magnet 32, the magnet magnetic path becomes shorter near the q-axis on the inner peripheral surface of the magnet 32. Therefore, in consideration of the fact that it is difficult to generate sufficient magnetic flux in the magnet 32 at a location where the magnet magnetic path length is short, the magnet is removed at a location where the magnet magnetic flux is weak. Note that in this embodiment, the recess 36 may or may not be formed.

Further, the inner circumferential surface (armature side circumferential surface) of the magnet 32 is covered with a thin protective sheet 41 as a protective member. The protective sheet 41 is made of non-magnetic metal or copper with low magnetic resistance. Note that the protective sheet 41 may be made of resin or the like.

Next, a method for manufacturing the magnet unit 22 among the methods for manufacturing the rotating electrical machine in this embodiment will be described.

First, the outline of the method for manufacturing the magnet 32 will be explained. Each magnet 32 is a sintered magnet manufactured by a sintering method. That is, the generated raw materials such as neodymium, boron, and iron are melted and alloyed (first step). Next, the alloy obtained in the first step is pulverized into particles (second step). Then, the powder obtained in the second step is put into a mold and pressure-molded in a magnetic field (third step). By being molded in this mold, the cross-sectional shape of the magnet 32 is made approximately arcuate. After pressure molding, the molded product is sintered (fourth step), and after sintering is heat treated (fifth step). In the heat treatment, heating and cooling are performed several times. Then, mechanical processing such as grinding and surface processing are performed (sixth step). Thereafter, each magnet 32 is completed by being magnetized (seventh step).

Next, a process for assembling the magnet unit 22 by assembling the thus completed magnets 32 will be described based on FIGS. 8 and 9.

First, as shown in FIG. 9A, a coupling step (step S11) is performed in which the q-axis side end faces of the magnetized magnets 32 are attracted to each other by magnetic force to form a magnet combination 81.

Next, as shown in FIG. 9(b), the magnet assembly 81 is attached to the inner peripheral surface (magnet holding surface) of the magnet holder 31 along the circumferential direction, with a gap corresponding to the circumferential dimension of the magnet assembly 81. A first fixing step (step S12) of arranging every other magnet assembly 81 and fixing it with adhesive 37 is performed so that 82 is formed. In the first fixing step, half of all the magnet couples 81 are fixed. Although the adhesive 37 is a room-temperature adhesive (for example, an adhesive that hardens at an ambient temperature of 50 degrees Celsius or lower), any adhesive may be used, and a thermosetting adhesive may also be used. Alternatively, a resin adhesive may be used. Alternatively, an adhesive sheet may be used. The elastic modulus of this adhesive 37 is desirably 500 MPa or less at 20°C.

As shown in FIG. 9(c), the remaining magnet combinations 81 are placed in the gaps 82 between the magnet combinations 81 formed in the first fixing step, and the inner peripheral surface of the magnet holder 31 is bonded with adhesive 37. A second fixing step (step S13) is performed to fix the magnet combinations 81.

In the second fixing process, when placing another magnet combination 81 in the gap 82 between the magnet combinations 81 arranged every other time, the same poles face each other on the d-axis, so that they are adjacent (newly The magnet combination 81 (disposed) will be repelled. Therefore, in this embodiment, each newly placed magnet 32 is held using a jig or the like so that the magnet assembly 81 does not move until the adhesive 37 hardens. Note that, as described above, the d-axis side side surfaces of the magnets 32 repel each other on the d-axis, so that they are spaced apart to form the inter-magnet gap 39. The inter-magnet gap 39 of each magnet 32 communicates with the recess 35, as shown in FIG. 9(c).

Thereafter, a filling step (step S14) is performed in which the inter-magnet gaps 39 and the recesses 35 are filled with resin. In this filling step, on the d-axis side of each magnet 32, resin is poured into the recess 35 formed on the outer peripheral surface side (opposite the armature side) and filled, thereby creating an inter-magnet gap 39 communicating with the recess 35. Let the resin flow out and fill it with resin. As a result, the resin member 38 is formed between the side surfaces of the magnet 32 on the d-axis side.

After the filling process, a protection process (step S15) is performed in which the inner peripheral surface of the magnet 32 is covered with a protection sheet 41. Thereby, the magnet unit 22 as shown in FIG. 7 is completed. After the magnet unit 22 is completed, the rotor 20 is assembled by assembling it to the rotor carrier 21, and the rotor 20, stator unit 50, etc. are combined to complete the rotating electric machine 10.

According to the first embodiment, the following effects can be obtained.

The magnet 32 is oriented so that the direction of the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, compared to the q-axis side, which is the boundary between the magnetic poles, and the magnet 32 A road is formed. The magnet 32 is divided along the d-axis and the q-axis. Therefore, the q-axis side surfaces of the magnets 32 are attracted to each other by magnetic force. On the other hand, the d-axis side surfaces repel each other due to magnetic force.

Therefore, when fixing the magnets 32 to the inner circumferential surface of the magnet holder 31, the q-axis side surfaces of the magnets 32 are attracted to each other, while the d-axis side surfaces are spaced apart from each other. This makes it easier to fix the magnet 32 to the magnet holder 31. Further, by filling the inter-magnet gap 39 between the d-axis side side surfaces of the magnets 32 with resin to form the resin member 38, there is no gap between the magnets 32, and positional displacement in the circumferential direction can be prevented. . This prevents the magnet 32 from shifting in the circumferential direction and applying circumferential stress to the adhesive 37, thereby preventing the adhesive force from weakening and the magnet 32 from falling off.

On the d-axis side of each magnet 32, a corner of the outer peripheral surface (on the side opposite to the armature) is chamfered to form a recess 35 along the axial direction. A resin member 38 is arranged so as to fill this recess 35. Therefore, the resin member 38 can have a certain thickness in the circumferential direction, and can effectively function as a rotation stopper for the magnet 32 in the circumferential direction. In addition, on the d-axis side of each magnet 32, the corners of the outer circumferential surface (counter-armature side) are parts where the magnet magnetic path tends to be shortened, so even if these corners are removed, there is no effect on the magnetic flux density. Therefore, the amount of magnets can be suitably reduced.

When assembling the magnet unit 22, first, in a joining step, the q-axis side end faces of the magnets 32 are attracted to each other by magnetic force to form the magnet combination 81. For this reason, compared to the case where the magnets 32 are arranged individually, it is possible to prevent the q-axis side end faces of the magnets 32 from adhering to each other and shifting their positions in the circumferential direction, making assembly easier.

In addition, in the first fixing step, the magnet assembly 81 is fixed on the inner peripheral surface of the magnet holder 31 along the circumferential direction so that a gap 82 corresponding to the circumferential dimension of the magnet assembly 81 is formed. Magnet combinations 81 are arranged at intervals and fixed with adhesive 37. That is, in the d-axis, since the magnet combinations 81 having the same polarity are fixed with the adhesive 37 without being arranged, the magnets can be fixed more easily than when they are fixed adjacent to each other.

Thereafter, the remaining magnet combinations 81 are arranged in the gaps 82 between the magnet combinations 81 formed in the first fixing step and fixed to the magnet holder 31 with the adhesive 37. That is, since one of the magnet combinations 81 that are adjacent to each other on the d-axis and have the same polarity is already fixed, it can be fixed more easily than when both are held until they are bonded.

In addition, in the filling process, on the d-axis side of each magnet 32, the resin is filled from the recess 35 formed on the outer peripheral surface side (the side opposite to the armature), and the inter-magnet gap 39 communicating with the recess 35 is filled with the resin. . Therefore, even if the inter-magnet gap 39 formed on the d-axis side is small, it is easy to fill it with resin.

Further, the inner circumferential surface (armature side circumferential surface) of each magnet 32 is covered with a protective sheet 41, and the axial end surface is covered with an end plate 33. Therefore, it is possible to suitably prevent the magnet 32 from falling off.

(Modified example)
A part of the configuration of the above embodiment may be changed. Modifications will be described below.

- In the above embodiment, the shapes of the magnet holder 31 and the rotor carrier 21 may be changed. For example, the magnet holder 31 may be configured integrally with the cylindrical portion 23 of the rotor carrier 21. That is, the magnet 32 may be fixed to the inner peripheral surface of the cylindrical portion 23. The cylindrical portion 23 of the rotor carrier 21 corresponds to a magnet holding portion.

Alternatively, as shown in FIG. 10, a rotor carrier 121 may be employed, which is configured in a cylindrical shape with a bottom and has a flange 121a extending radially outward at the outer edge of the opening. In this case, the magnet unit 22 such as the magnet 32 is fixed to the inner peripheral surface of the cylindrical portion 123 of the rotor carrier 121.

- In the above embodiment, the configuration of the protective sheet 41 that covers the inner peripheral surface of the magnet 32 may be arbitrarily changed. For example, as shown in FIG. 11, a ring member 141 made of non-magnetic metal may be press-fitted into the inner circumferential surface of the magnet unit 22 to cover the inner circumferential surface of the magnet unit 22. Note that by press-fitting into the inner circumferential surface side of the magnet unit 22, the magnet 32 is pressed radially outward, and the magnet 32 is pressed against the inner circumferential surface (magnet holding surface) of the magnet holder 31 (or rotor carrier 121). be able to. Therefore, it is possible to suitably prevent the magnet 32 from falling off.

Further, as shown in FIG. 11, a flange portion 142 may be provided on the outer periphery of one end of the ring member 141 in the axial direction. In this case, as shown in FIG. 12, by press-fitting into the inner peripheral surface of the magnet 32, the flange portion 142 can cover the axial end surface of the magnet 32 and prevent it from falling off. Note that the ring member 141 can be fixed by fixing the flange portion 142 to the flange portion 121a of the rotor carrier 121 by adhesive or the like.

Furthermore, a flange portion 143 may be provided on the inner periphery of the other end of the ring member 141. In this case, by fixing the flange portion 142 to the bottom portion 121b of the rotor carrier 121 by adhesive or the like, the ring member 141 can be more firmly fixed. Note that if a gap is formed between the ring member 141 and the magnet 32 (for example, between the flange portion 142 and the axial end face of the magnet 32), it is desirable to fill it with resin or the like.

Further, in this modification, the ring member 141 is configured in an annular shape, but it may also be in a C-shape with a portion interrupted. Further, the ring member 141 may be divided into a plurality of parts in the circumferential direction.

- In the above embodiment, the magnet 32 may be divided in the axial direction, and the gaps in the axial direction may be insulated by filling with resin, adhering, plating, painting, etc.

- In the above embodiment, one axial end of the protective sheet 41 may be fixed to the flange portion 121a of the rotor carrier 121 by adhesive or the like, similarly to the ring member 141 described above. Similarly, the other axial end of the protective sheet 41 may be fixed to the bottom 121b of the rotor carrier 121 by adhesive or the like. This allows for more secure fixing.

- In the above embodiment, the end plate 33 is provided at one axial end of the magnet unit 22 to prevent it from falling off, but the end plate 33 is provided at one axial end of the magnet unit 22 to prevent it from falling off. , a protrusion may be provided to restrict movement of the magnet 32 in the axial direction. For example, as shown in FIG. 13, a protrusion 151 may be provided at the open end of the rotor carrier 21 to restrict movement of the magnet unit 22 in the axial direction. It is desirable that the protrusion 151 be caulked and fixed to the axial end surface side of the magnet 32 after the magnet 32 is fixed.

- In the above embodiment, the protective sheet 41 may be made of resin, and the protective sheet 41 and the resin member 38 may be integrally formed. That is, the entire inner circumferential surface (armature side circumferential surface) of the magnet 32 may be covered with resin, and the inter-magnet gap 39 and recess 35 of the magnet 32 may be filled with resin.
- In the above embodiment, the inner peripheral surface (armature side peripheral surface) of the magnet 32 may be coated to form a protective sheet.
- In the above embodiment, since the q-axis side surfaces of the magnets are in contact with each other, there is no need to perform surface treatment (rust prevention treatment, etc.) on the q-axis side surfaces of the magnets.

- In the above embodiment, the magnet 32 is divided along the d-axis and the q-axis, but it may be configured such that it is divided only along the d-axis. In other words, a magnet corresponding to the magnet combination 81 may be adopted in which both ends of the magnet 32 in the circumferential direction are the d-axis and the center is the q-axis. In other words, one magnet 32 may be provided between two circumferentially adjacent magnetic poles between the d axes, which are the centers of the respective magnetic poles. In this case, when assembling the magnet unit 22, the joining step (step S11) can be omitted. Note that the other assembly steps are the same as those in the above embodiment, and therefore the description thereof will be omitted. This makes assembly easier.

- In the above embodiment, an adhesive reservoir, which is a space in which the adhesive 37 accumulates, may be provided between the d-axis and the q-axis. That is, the outer circumferential surface of the magnet 32 (the opposing surface facing the inner circumferential surface of the magnet holder 31 ) is formed with the same curvature as the curvature of the inner circumferential surface of the magnet holder 31 . On the other hand, a part of the outer peripheral surface of the magnet 32 is configured to be spaced apart from the inner peripheral surface (magnet holding surface) of the magnet holder 31 in the radial direction. For example, as shown in FIG. 14, on the outer peripheral surface of the magnet 32, a flat portion is provided at the central portion (the intermediate portion between the d-axis and the q-axis), and the inner peripheral surface of the magnet holder 31 ( The magnet holder 31 is spaced apart in the radial direction from the magnet holding surface (magnet holding surface), and is configured to form a gap with the inner circumferential surface of the magnet holder 31 . The gap thus formed is used as an adhesive reservoir 160. This makes it possible to further strengthen the adhesive force. In addition, in FIG. 14, the adhesive reservoir 160 is illustrated to be emphasized in order to make the explanation easier to understand.

DESCRIPTION OF SYMBOLS 10... Rotating electric machine, 20... Rotor, 22... Magnet unit, 31... Magnet holder, 32... Magnet, 37... Adhesive, 38... Resin member, 60... Stator, 61... Stator winding, 81... Magnet coupling body.

Claims (10)

A field element (20) having a magnet portion (22) including a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), In a rotating electric machine (10) in which one of the field element and the armature is a rotor,
The magnet portion includes a plurality of magnets (32) arranged side by side in the circumferential direction, and a magnet holding portion (31) to which the plurality of magnets are fixed,
The magnet is oriented such that on the d-axis side, which is the center of the magnetic pole, the direction of the axis of easy magnetization is parallel to the d-axis, compared to the q-axis side, which is the boundary between the magnetic poles. A road has been formed,
The magnet holding part is fixed to its magnet holding surface with an adhesive (37) in a state in which a plurality of the magnets are arranged side by side in the circumferential direction,
In the rotating electric machine, the magnets are separated at least along the d-axis, and an inter-magnet gap (39) between the circumferentially adjacent magnets on the d-axis is filled with a resin member (38). The rotating electric machine according to claim 1, wherein the magnets are separated in the d-axis and the q-axis, and the magnets that are circumferentially adjacent to each other in the q-axis are fixed in contact with each other. The magnet part has a protection member (41, 141) that covers and protects the armature side peripheral surface of the magnet,
The rotating electric machine according to claim 1 or 2, wherein the protection member is in pressure contact with the magnet so as to press the magnet toward the magnet holding portion in a radial direction. The magnet part has a protection member (141) that covers and protects the armature side peripheral surface of the magnet,
Any one of claims 1 to 3, wherein the protective member has a radially projecting flange portion (142) on at least one of both axial ends so as to cover an axial end surface of the magnet portion. The rotating electric machine described in . The magnet part has a protection member that covers and protects the armature side peripheral surface of the magnet,
The rotating electrical machine according to any one of claims 1 to 4, wherein the protective member is made of resin and is integrated with a resin member that fills the gap between the magnets on the d-axis. The opposing surface of the magnet that faces the magnet holding surface is spaced apart from the magnet holding surface of the magnet holding portion in the radial direction between the d-axis and the q-axis, and the gap thus formed is The rotating electric machine according to any one of claims 1 to 5, which is used as an adhesive reservoir (160). The rotating device according to any one of claims 1 to 6, wherein on the d-axis side of each of the magnets, a corner on the opposite armature side is chamfered to form a recess (35) along the axial direction. Electric machine. A field element (20) having a magnet portion (22) including a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), In a method for manufacturing a rotating electrical machine (10) in which one of the field element and the armature is a rotor,
The magnet portion includes a plurality of magnets (32) arranged side by side in the circumferential direction, and a magnet holding portion (31) to which the plurality of magnets are fixed,
The magnet is divided along the d-axis, and is oriented such that the axis of easy magnetization on the d-axis side, which is the magnetic pole center, is more parallel to the d-axis than on the q-axis side, which is the magnetic pole boundary. , a magnet magnetic path is formed along the axis of easy magnetization,
Arranging every other magnet on the magnet holding surface of the magnet holding part along the circumferential direction so that a gap (82) corresponding to the circumferential dimension of the magnet is formed, a first fixing step (S12) of fixing with adhesive;
The magnets are placed in the gaps between the magnets formed in the first fixing step so that a predetermined inter-magnet gap is formed between the d-axes of circumferentially adjacent magnets, and the magnets are fixed with adhesive. a second fixing step (S13) of fixing to the magnet holding surface of the holding part;
A method for manufacturing a rotating electric machine, comprising a filling step (S14) of filling a predetermined inter-magnet gap formed in the second fixing step with resin. A field element (20) having a magnet portion (22) including a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), In a method for manufacturing a rotating electrical machine (10) in which one of the field element and the armature is a rotor,
The magnet portion includes a plurality of magnets (32) arranged side by side in the circumferential direction, and a magnet holding portion (31) to which the plurality of magnets are fixed,
The magnet is divided along the d-axis and the q-axis, and the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary. The magnetic path is oriented along the axis of easy magnetization.
a coupling step (S11) of making the q-axis side end surfaces of the magnets attract each other by magnetic force to form a magnet combination (81);
The magnet coupling is attached every other magnet so that a gap (82) corresponding to the circumferential dimension of the magnet coupling is formed on the magnet holding surface of the magnet holding part along the circumferential direction of the magnet coupling. a first fixing step (S12) of arranging the body and fixing it with adhesive;
The magnet combinations are placed in the gaps between the magnet combinations formed in the first fixing step so that a predetermined inter-magnet gap is formed between the d-axes of circumferentially adjacent magnets, and the magnet combinations are bonded. a second fixing step (S13) of fixing to the magnet holding surface of the magnet holding part with a compound;
A method for manufacturing a rotating electric machine, comprising a filling step (S14) of filling a predetermined inter-magnet gap formed in the second fixing step with resin. On the d-axis side of each of the magnets, a corner on the opposite armature side is chamfered to form a recess (35) along the axial direction,
9. In the filling step, the inter-magnet gap formed between the d-axes is filled with resin from the recess formed on the opposite armature side on the d-axis side of each of the magnets. Or the method for manufacturing a rotating electric machine according to 9.

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