JP2024017909A - Ipm motor, rotor thereof, rotor core basic structure, and rotor forming method - Google Patents

Abstract

To provide an IPM motor manufacturing technology that can improve workability in a magnet insertion process.SOLUTION: An IPM motor rotor core basic structure 5 is a structure for forming an IPM motor with a rotor core consisting of multiple core pieces 1, the multiple core pieces 1, which are the basic units of rotor core formation, are connected, and each of the core pieces 1 is provided with an insertion hole 2 for inserting a magnet, and adjacent core pieces 1-1 form a joint 3 that bendably connects the respective outer peripheral corners.SELECTED DRAWING: Figure 1

Description

The present invention relates to an IPM motor, its rotor, rotor core basic structure, and rotor forming method, and particularly relates to a rotor of an IPM motor that can improve workability in a rotor forming process.

Conventionally, methods for arranging magnets on a rotor in a motor include a SPM (Surfacial Permanent Magnet) structure, which is constructed by pasting segment magnets on the rotor surface or using ring magnets, and embedding magnets in the rotor. It may be based on an IPM (Internal Permanent Magnet) structure. Conventionally, many patent applications have been filed regarding rotor structures for IPM motors.

For example, in Patent Document 1 by the applicant listed below, for the purpose of reducing cogging torque, etc. in an IPM motor having a Halbach arrangement, a plurality of segment magnets are formed in a continuous arrangement of poles formed in a surrounding shape, and each pole is consists of one bottom and two walls provided at both ends, and the outer edges between all the two walls in the cross-sectional shape of the rotor are centered on the axis and the outermost point of the outer edge is the center of the rotor. A configuration is disclosed in which the arc is formed by an arc of a circle having a larger curvature than the arc of the circle passing through.

FIG. 5 is an explanatory diagram showing a method for manufacturing a rotor 510 of a motor having this IPM structure, in which (a) is a side view showing the method, and (b) is a plan view of the manufactured rotor 510. As shown in the figure, the rotor core 55 is of course ring-shaped, and a magnetized magnet 56 is inserted into the magnet insertion hole 52 to form a rotor 510.

Further, Patent Document 2 discloses that at least one of a plurality of rotor core members forming a rotor core by lamination is used as a rotor for an IPM motor in which a rotor magnet can be easily inserted into a magnet insertion hole and movement within the hole can be suppressed. discloses a configuration including a protrusion that forms a part of the inner edge of the magnet insertion hole and comes into contact with a rotor magnet inserted into the protrusion, and a protrusion deformation permitting part that is provided on the opposite side with the protrusion interposed therebetween. ing.

Patent No. 6283788 "Rotor structure of IPM motor, rotor and IPM motor" Japanese Patent Application Publication No. 2021-164174 “Rotor for IPM motor”

As mentioned above, in the IPM structure disclosed in Document 1, a method is used in which a magnetized magnet is inserted into a magnet insertion hole, but inserting a magnetized magnet into a rotor core causes the poles of the magnets to repel each other. Therefore, it is difficult. That is, the workability of the magnet insertion process in rotor manufacturing is poor, and improvements in workability have been desired.

Therefore, the problem to be solved by the present invention is to provide an IPM motor and its manufacturing technology that can eliminate the problems of the prior art and improve workability in the magnet insertion process.

As a result of studying the above-mentioned problems, the inventor of the present application has proposed that a rotor is formed by using a deformable rotor core, inserting a magnet in an unmagnetized state into an insertion hole, then magnetizing it, and deforming the rotor core after magnetization. We have found that the problem can be solved by a method, and based on this we have completed the present invention. That is, the invention claimed or at least disclosed in this application as a means for solving the above problems is as follows.

[1] A rotor core basic structure for an IPM motor equipped with a rotor core consisting of a plurality of core pieces, in which a plurality of the core pieces, which are the basic units for forming the rotor core, are connected, and the core piece has an insertion hole for inserting a magnet. A rotor core basic structure for an IPM motor, characterized in that adjacent core pieces form joints that bendably connect corners on the outer circumferential side.
[2] A rotor for an IPM motor, characterized in that the rotor core basic structure according to [1] is curved inward to form an annular shape, and a magnet is inserted into an insertion hole of the core piece.
[3] The rotor of the IPM motor according to [2], wherein the magnet is magnetized to form a Halbach array.
[4] An IPM motor comprising the rotor according to any one of [2] and [3].

[5] Using the rotor core basic structure described in [1], a magnet insertion process of inserting a magnet into the insertion hole, and curving the rotor core basic structure into which the magnet is inserted into an annular shape, and forming a ring shape at both ends. 1. A method for forming a rotor of an IPM motor, comprising: forming a ring shape to connect parts.
[6] The method for forming a rotor for an IPM motor according to [5], characterized in that the magnet insertion step includes inserting an unmagnetized magnet, and then including a magnetization step of magnetizing the magnet.
[7] The method for forming a rotor for an IPM motor according to [6], wherein in the magnetization process, magnetization is performed so as to have a Halbach array.

Since the IPM motor, its rotor, rotor core basic structure, and rotor forming method of the present invention are configured as described above, the workability in the magnet insertion process can be improved.

FIG. 2 is an explanatory plan view showing a configuration example of a rotor core basic structure of an IPM motor of the present invention. FIG. 2 is an explanatory plan view showing the configuration of the rotor of the IPM motor of the present invention. FIG. 2 is a flow diagram showing the configuration of a method for forming a rotor for an IPM motor according to the present invention. FIG. 3 is an explanatory plan view showing a magnetization process that constitutes the method for forming a rotor of an IPM motor according to the present invention. FIG. 2 is an explanatory diagram showing a conventional method for manufacturing a rotor of an IPM motor.

Hereinafter, the present invention will be explained in detail with reference to the drawings.
FIG. 1 is an explanatory plan view showing a configuration example of a rotor core basic structure of an IPM motor according to the present invention. Further, FIG. 2 is an explanatory plan view showing the configuration of the rotor of the IPM motor of the present invention. As shown in these figures, the rotor core basic structure 5 of the present IPM motor is a structure for forming an IPM motor equipped with a rotor core 10 consisting of a plurality of core pieces 1, 1, . . . , and is a basic unit for forming the rotor core 10. A plurality of core pieces 1 are connected, and each core piece 1 is provided with an insertion hole 2 for inserting a magnet 6, and the corners of each outer circumferential side are connected bendably between adjacent core pieces 1-1. The main configuration is that it forms a joint part 3.

The rotor core basic structure 5 of the present IPM motor having such a configuration has insertion holes 2, 2, 2 provided in each of the plurality of connected core pieces 1, 1, 1, . . . as described later in the explanation with reference to FIG. , ... are inserted into the magnets 6, 6, 6, ..., and then the joints 3, 3, ... are bent toward the inner peripheral side of the core pieces 1, 1, ... to form the rotor core basic structure. The whole 5 is formed in an annular shape, which ultimately results in the formation of a rotor core 10. That is, an annular rotor core 10 is formed using an elongated rotor core basic structure 5 having both ends.

Since the joint portion 3 is sandwiched between the main bodies of the core pieces 1 and 1 on the left and right sides and is formed thin, it can be easily bent inward. The core piece 1 can also be said to have a divided structure for forming the rotor core 10. Although the rotor core basic structure 5 is made up of 20 core pieces 1 in FIGS. 1 and 2, this number is not limited and can be set to an appropriate number as long as the final ring shape can be formed smoothly. can.

As shown in FIG. 2, the rotor core basic structure 5 is curved inward to form an annular shape, and is inserted into each insertion hole 2, 2, 2, . . . of the core pieces 1, 1, 1, . An IPM motor having a rotor core 10 into which magnets 6, 6, 6, . . . are inserted, and its rotor are also within the scope of the present invention. Moreover, the magnets 6, 6, 6, . . . can be configured to be magnetized to form a Halbach array.

FIG. 3 is a flow diagram showing the configuration of a method for forming a rotor for an IPM motor according to the present invention. As shown in the figure, the present IPM motor rotor forming method uses a rotor core basic structure 5 having one of the configurations described above, and includes a magnet insertion step P10 in which a magnet 6 is inserted into an insertion hole 2, and a magnet 6 is inserted. The main configuration includes an annular forming process P20 in which the rotor core basic structure 5 is curved inward to form an annular shape and both ends are connected.

According to this flow having such a configuration, the magnets 6, 6, 6, . . . are inserted into the respective insertion holes 2, 2, 2, . In step P20, the rotor core basic structure 5 into which the magnet 6 has been inserted is curved inward to form an annular shape, and both ends thereof are connected to form an annular shape, thereby obtaining the rotor core 10.

The present rotor forming method may have a flow including a magnet insertion step P10 in which an unmagnetized magnet is inserted, and then a magnetization step P15 in which the magnet is magnetized as shown in FIG. In other words, by inserting unmagnetized magnets 6, 6, 6, ... into the insertion holes 2, 2, 2, ..., the magnets will not touch each other when inserting magnetized magnets 6. The insertion operation can be performed smoothly without causing any repulsion or suction. Workability can be improved.

After the insertion of all the magnets 6, 6, 6, . Magnetize accordingly. By carrying out the magnet insertion process P10 and the magnetization process P15, the workability in manufacturing the rotor core 10 can be improved. Note that after the magnetization process P15, an annular forming process P20 is performed as shown in the figure.

Note that FIG. 4 is an explanatory plan view showing the magnetization process P15 that constitutes the method for forming a rotor of an IPM motor according to the present invention. In this way, before the ring shape is formed in the ring shape forming process P20, the unmagnetized magnets 6, 6, 6, ... are inserted into the insertion holes 2, 2, 2, ... (magnet insertion process P10), and then subjected to a magnetization process P15.

According to the IPM motor, its rotor, rotor core basic structure, and rotor forming method of the present invention, workability in the magnet insertion process can be improved. Therefore, the present invention has high industrial applicability in the field of manufacturing and using IPM motors including AC servo motors, especially in the FA field and all related fields.

1... Core piece 2... Insertion hole 3... Joint part 5... Rotor core basic structure of IPM motor 6... Magnet 10... Rotor core P10... Magnet insertion process P15... Magnetization process P20... Annular formation process 52... Magnet insertion hole 55... Rotor core 56... Magnet 58...Motor shaft 510...Rotor

Claims (7)

A rotor core basic structure for an IPM motor having a rotor core composed of a plurality of core pieces,
A plurality of core pieces, which are the basic unit of rotor core formation, are connected,
The core piece is provided with an insertion hole for inserting a magnet,
A rotor core basic structure for an IPM motor, characterized in that adjacent core pieces form joints that bendably connect corners on each outer circumferential side. The rotor core basic structure according to claim 1 is curved inwardly to form an annular shape,
A rotor for an IPM motor, characterized in that a magnet is inserted into an insertion hole of the core piece. 3. The rotor of an IPM motor according to claim 2, wherein the magnet is magnetized to form a Halbach array. An IPM motor comprising the rotor according to claim 2 or 3. Using the rotor core basic structure according to claim 1,
a magnet insertion step of inserting a magnet into the insertion hole;
an annular-forming process of curving the rotor core basic structure into which the magnet is inserted inward to form an annular shape and connecting both ends;
A method for forming a rotor of an IPM motor, comprising: 6. The method of forming a rotor for an IPM motor according to claim 5, wherein the magnet insertion step includes inserting an unmagnetized magnet, and then including a magnetization step of magnetizing the magnet. 7. The method of forming a rotor for an IPM motor according to claim 6, wherein in the magnetization process, magnetization is performed so as to have a Halbach array.