JP5289415B2 - Method for manufacturing synchronous motor - Google Patents

Description

The present invention includes a stator winding of the two phases, relates to a manufacturing method of a synchronous motor having a rotor having a plurality of magnetic poles made of permanent magnets.

  As a blower motor such as a ventilation fan, a single-phase induction motor that is robust and does not require a drive control device and is inexpensive is used. In the field of blowers, since the amount of single-phase induction motors used is overwhelmingly large, capital investment specializing in induction motors is made, and automated production is usually performed. For example, a conventional induction motor for automated production is designed for the purpose of saving resources and reducing copper loss by “inserting an inner ring magnetic pole portion 10 composed of a plurality of magnetic pole pieces 7 into an outer ring yoke portion 5 that forms an outer ring portion”. 6, the insulating resin including the coil guard 16 protruding from one end face of the inner ring magnetic pole portion 10 and having the insertion groove of the insulating wedge 31 provided on the side wall is molded and fixed. Inserted into the magnetic pole portion 10, the rotor 17 has a pin main body 25 and is covered with an insulating governor 19 composed of a winding column 20 composed of an outer pole 24 and an inner pole 23, and the inner pole 23 and the center of the inner ring magnetic pole portion 10. The coil 26 is wound between the two. "(For example, see Patent Document 1).

  In recent years, due to the growing interest in energy saving and comfort, products with low airflow operation and low airflow long-time continuous (24-hour operation) functions are preferred. In that case, it is necessary to make the air flow variable. 2. Description of the Related Art Conventionally, an induction motor drive device for an induction motor that continuously varies the amount of air flow is, for example, “the main winding 152 and the start winding 154 of the single-phase two-winding induction motor 150 are the first phase voltage of the two-phase power Connected to both ends of VP1 and second phase voltage VP2. The windings 152 and 154 are connected by a common winding 156. A two-phase power source drives the motor 150 with a preferred phase angle. " (For example, refer to Patent Document 2).

  Also, for example, a motor 4 having a two-phase stator winding (main winding 4a and auxiliary winding 4b) is supplemented by a six-stone inverter circuit 3 with reference to the voltage waveform Vm of the main winding 4a. The voltage phase of the voltage waveform Va of the winding 4b, the voltage phase of the voltage waveform Vc of the common terminal 5c of the two-phase winding, and the voltage peak value can be freely adjusted, respectively. " 3).

JP 6-6959 A (summary) JP-A-6-54585 (summary) Japanese Patent Laying-Open No. 2005-184885 (summary)

In the induction motor, copper loss occurs in the rotor, and it is impossible in principle to eliminate the loss. On the other hand, in a synchronous motor using a rotor having a plurality of magnetic poles with permanent magnets (hereinafter also referred to as “magnet rotor”), copper loss in the rotor does not occur in principle, so a synchronous motor (hereinafter referred to as “motor”). (Also referred to as) a single loss can be reduced.
For this reason, the copper loss of a rotor can be eliminated by making the rotor of an induction motor operate as a synchronous rotor with a magnet rotor. However, a synchronous motor, in principle, does not generate torque continuously unless the rotating magnetic field generated by the stator (hereinafter also referred to as “stator”) and the magnetic pole of the rotor are synchronized. It is necessary to control the rotating magnetic field.
Usually, in a synchronous motor used for a blower or the like, a magnetic pole position detection sensor (hereinafter also referred to as “sensor”) for detecting the magnetic pole position of the rotor is built in the motor, and the rotating magnetic field is controlled based on the signal. The method is used.

  However, for example, as shown in Patent Document 1, in an electric motor structure suitable for automatic production with a small amount of copper, winding is performed in a state where the rotor and the stator are combined. Covered with a cover, the sensor cannot be attached in the vicinity thereof. In order to mount the sensor, it is necessary to change the structure of the electric motor or to produce it by hand machining. When the structure of the electric motor is changed, a new automated production facility is required, and when it is produced by manual machining, the productivity is low and the machining cost is remarkably increased.

In addition, in general induction motors, the coil end of the stator is large, so the amount of leakage magnetic flux is large in the vicinity of the induction motor, and if a sensor is placed at the end of the stator, it is possible to avoid a decrease in reliability due to malfunction. It becomes a problem. In general, the magnetic force of the magnet of the stator is increased to increase the magnetic flux density inputted to the sensor. In this case, however, the price of the magnet is remarkably increased.
In addition, there is a method that uses a concentrated winding method for the stator winding so as to reduce the coil end, but this winding method cannot be used for induction motors used in blowers and the like that require quietness. An electric motor and a synchronous motor cannot be manufactured on the same production line. In this case, production facilities for both the induction motor and the synchronous motor are required, and when the production amounts of both are unbalanced, it becomes difficult to recover the production facility costs of the motor with the smaller production volume.

  In recent years, contractors have struggled to dispose of industrial waste when dismantling houses, and motors for ventilation fans with high recycling performance are preferred. Even if a structure capable of incorporating the sensor is obtained, the sensor is usually realized by mounting a sensor element using a compound semiconductor such as gallium arsenide or indium antimony on an electronic circuit board. When a sensor is built in, the disassembly / classification factor at the time of recycling increases, which deteriorates recyclability and is not preferred by contractors.

  In addition, in the conventional two-phase induction motor driving device as shown in Patent Documents 2 and 3, for example, there is no function of controlling the rotating magnetic field in accordance with the state of the rotor. It is impossible to drive the magnet rotor as a synchronous motor. In addition, a general synchronous motor uses a three-phase motor with good controllability, and a control technology for low-noise and high-efficiency magnetic pole position detection sensorless operation has been developed for a two-phase synchronous motor. There wasn't. For this reason, in order to use a three-phase motor, a production facility different from the current two-phase motor is required, and the total cost of the motor plus the production facility cost is greatly increased. This is particularly true for ventilation fans and pumps that are currently producing and mounting two-phase induction motors in large quantities.

  Thus, when the rotor of the two-phase induction motor is a rotor having a plurality of magnetic poles by permanent magnets and operated as a synchronous motor, the two-phase induction motor is not provided with a sensor or the like for detecting the magnetic pole position of the rotor. There was a problem that the synchronous motor could not be operated.

The present invention has been made to solve the above-described problems, and an object of the present invention is to obtain a method of manufacturing a synchronous motor that has a small amount of copper and is suitable for automatic production.
It is another object of the present invention to provide a method for manufacturing a synchronous motor that can be produced in an automated production facility for induction motors .

A method of manufacturing a synchronous motor according to the present invention includes a stator having a two-phase stator winding composed of a first winding and a second winding, and a rotor having a plurality of magnetic poles by permanent magnets, A method of manufacturing a synchronous motor controlled to operate synchronously without detecting means for detecting the magnetic pole position of the rotor, wherein the rotor is magnetized to form a plurality of magnetic poles, and the stator The rotor is inserted into the teeth, the stator and the rotor are combined , and then an insulating cover that performs insulation between the stator teeth and the stator winding is provided with the stator teeth. After that, the stator winding is wound.

According to the present invention, a synchronous motor having a small amount of copper and suitable for automatic production can be obtained.
Further, since no detection means for detecting the magnetic pole position is provided in the vicinity of the rotor, a synchronous motor can be produced in an automated production facility for induction motors.

1 is a circuit diagram of a motor and a motor drive control device according to Embodiment 1. FIG. FIG. 3 is a block diagram showing a configuration of sensorless control means according to the first embodiment. 3 is a structural diagram of a stator and a rotor of the motor according to Embodiment 1. FIG. It is the figure which showed typically the cross section of the ventilation fan which concerns on Embodiment 1. FIG. 6 is a circuit diagram of a motor and a motor drive control device according to Embodiment 2. FIG. It is the figure which showed typically the structure of the stator which concerns on Embodiment 3. FIG. It is a figure which shows the structure of the air conditioner which concerns on Embodiment 5. FIG. It is a figure which shows the structure of the refrigerator which concerns on Embodiment 6. FIG.

Embodiment 1 FIG.
FIG. 1 is a circuit diagram of a motor and a motor drive control device according to the first embodiment. In FIG. 1, the motor drive control device is composed of a rectifier circuit 2, an inverter circuit 5, a sensorless control means 10, and a current detection means 11, and is driven by electric power supplied from a commercial power supply 1. The operation of an electric motor (hereinafter referred to as “motor”) 7 is controlled.

  As for the commercial power source 1, 100 V 50 Hz or 60 Hz single-phase alternating current is generally used in a general Japanese home. Moreover, a single-phase alternating current of 200 V or more may be used for business use or overseas.

  The rectifier circuit 2 is a full-wave rectifier circuit, and converts the AC voltage of the commercial power supply 1 into a DC voltage. For example, when the commercial power source 1 is AC100V, it is converted to DC140V. This rectifier circuit 2 is configured by bridge-connecting four rectifier diodes 3a to 3d. Furthermore, it is smoothed by the electrolytic capacitor 4.

  The inverter circuit 5 receives the DC voltage output rectified by the rectifier circuit 2, performs PWM control by the operation of the sensorless control means 10 described later, and converts the input DC voltage into a three-phase AC of an arbitrary voltage and an arbitrary frequency. To do. The inverter circuit 5 is configured by bridge-connecting switching elements 6a to 6f such as FETs, for example. Each switching element 6a to 6f includes a high-speed diode in parallel in the reverse current direction. The built-in high-speed diode functions to flow a reflux current when the switching elements 6a to 6f are turned off. Furthermore, the inverter circuit 5 is provided with a shunt resistor 12 that converts the current of each arm of the switching element 6 into a voltage.

  The motor 7 is a 16-slot 4-pole two-phase synchronous motor (brushless DC motor: BLDCM), and drives a ventilation fan 100 (described later). The motor 7 has a main winding 8a that is a first winding and an auxiliary winding 8b that is a second winding. The main winding 8a and the auxiliary winding 8b (hereinafter referred to as “ A stator (not shown) having a two-phase winding whose one terminal is a common terminal, and a magnet rotor 9 which is a rotor having a plurality of magnetic poles made of permanent magnets. . The main winding 8a and the auxiliary winding 8b are arranged at mechanical positions that are 90 degrees out of phase. The motor 7 has a main winding terminal M, an auxiliary winding terminal S, and a common terminal C for each winding 8. Each terminal of the motor 7 is connected to the output terminal of the inverter circuit 5.

  The current detection means 11 amplifies and level shifts the current of each arm of the inverter circuit 5 converted into a voltage by the shunt resistors 12a, 12b and 12c of the inverter circuit 5, and outputs each arm current to the sensorless control means 10. It is.

  The sensorless control means 10 performs PWM (Pulse Width Modulation) by determining the switching time of the switching element 6 of the inverter circuit 5 from each arm current obtained from the current detection means 11, and performs each winding of the motor 7. By applying a voltage to the line 8 and controlling the winding current of the winding 8, a rotating magnetic field synchronized with the magnet rotor 9 is generated, and the motor 7 is driven and controlled.

  FIG. 2 is a block diagram showing the configuration of the sensorless control means according to the first embodiment. In FIG. 2, the sensorless control means 10 includes a current coordinate conversion unit 20, a current control unit 21, a voltage coordinate conversion unit 22, a slip compensation unit 25, a speed controller 26, a θe calculation unit 27, and a PWM signal. And generating means 33.

  The current coordinate conversion unit 20 converts each arm current input from the current detection means 11 into an αβ axis current conversion unit 23 that converts the αβ axis current into two-phase stationary coordinates, and converts the αβ axis current into a dq axis current idq. The dq-axis current conversion unit 24 converts the current input from the current detection means 11 into a d-axis current (id) that is an excitation current component and a q-axis current (iq) that is a torque current component. To do.

  The slip compensator 25 calculates a compensation amount ωd for compensating an angular velocity of a speed command value (described later) based on the torque current component (iq) of the dq axis current idq input from the current coordinate converter 20 to calculate a speed controller. 26.

  The speed controller 26 compensates the speed command value ωref, which is a target angular speed value given from the outside, using the compensation amount ωd input from the slip compensation unit 25, and is a primary speed command value after compensation. The angular velocity ω1 is calculated.

  The θe calculator 27 integrates the primary angular velocity ω1 to obtain the phase angle θe. This phase angle θe is used for coordinate conversion of the dq axis current converter 24 and the αβ axis voltage command converter 31.

  The current control unit 21 includes a current error calculation unit 28, a low pass filter 29, and a current controller 30. The current error calculation unit 28 calculates the error between the d-axis current command value id * given from the outside and the excitation current component (id) of the dq-axis current idq input from the current detection means 11 to calculate the current error ierr. Input to the current controller 30. The low-pass filter 29 removes the high frequency component of the dq-axis current idq input from the current detection unit 11 and inputs the filter pass value idq_fil which is the dq-axis current idq after passing through the filter to the current controller 30. The current controller 30 includes an externally supplied d-axis current command value id *, a compensation amount ωd obtained from the slip compensation unit 25, a current error ierr obtained from the current error calculation unit 28, and a low-pass filter 29. From the obtained filter passing value idq_fil, a dq axis voltage command Vdq which is an output voltage command value for driving the motor 7 is calculated.

  The voltage coordinate converter 22 uses the phase angle θe obtained from the θe calculator 27 to convert the dq axis voltage command Vdq into an αβ axis voltage command Vαβ that is a two-phase voltage command value. And an MCS axis voltage command conversion unit 32 that converts the αβ axis voltage command Vαβ into an MCS axis voltage command.

  The PWM signal generation means 33 generates switching signals Mp, Cp, Sp, Mn, Cn, and Sn for the switching elements 6 a to 6 f of the inverter circuit 5 from the MCS axis voltage command of the voltage coordinate conversion unit 22.

  Next, the operation of the motor drive control apparatus according to the first embodiment having such a configuration will be described with reference to FIGS. In FIG. 1, a current detection unit 11 amplifies and level shifts the shunt current of each arm detected by the shunt resistors 12a, 12b, and 12c of the inverter circuit 5, and performs sensorless control unit 10 as shunt currents iMs, iCs, and iSs. To enter. Using the shunt currents iMs, iCs, and iSs, the sensorless control means 10 obtains a voltage output from the inverter circuit 5 to drive the motor 7 by calculation, and controls the switching elements in the inverter circuit 5 on / off. Output a PWM signal.

  The sensorless control means 10 outputs a PWM signal by the operation described below. In FIG. 2, the current coordinate conversion unit 20 converts the shunt current detected by the current detection unit 11 into the winding currents iM and iS by the αβ axis current conversion unit 23, and then the αβ axis on the two-phase stationary coordinates. Convert to current. Next, the αβ-axis current is converted into a dq-axis current idq by the dq-axis current conversion unit 24 using the phase angle θe obtained from the θe calculation unit 27, and the slip compensation unit 25, the current error calculation unit 28, and the low-pass Input to the filter 29.

The slip compensator 25 calculates a compensation amount ωd for compensating the angular velocity of the speed command value based on the torque current component (iq) of the input dq-axis current idq and inputs it to the speed controller 26. The speed controller 26 calculates the primary frequency ω1 by taking the difference between the speed command value ωref and the compensation amount ωd and inputs the primary frequency ω1 to the θe calculator 27 and the current controller 30.
On the other hand, the current error calculation unit 28 calculates the error between the d-axis current command value id * given from the outside and the excitation current component (id) of the dq-axis current idq input from the current detection means 11 to calculate the current error. ierr is input to the current controller 30. The low-pass filter 29 removes the high frequency component of the dq-axis current idq input from the current detection unit 11 and inputs the filter pass value idq_fil which is the dq-axis current idq after passing through the filter to the current controller 30.

The current controller 30 includes an externally supplied d-axis current command value id *, a compensation amount ωd obtained from the slip compensation unit 25, a current error ierr obtained from the current error calculation unit 28, and a low-pass filter 29. A dq axis voltage command Vdq for driving the motor 7 is calculated from the obtained filter passage value idq_fil.
Next, the voltage coordinate conversion unit 22 converts the dq axis voltage command Vdq into the αβ axis voltage command Vαβ by using the phase angle θe obtained from the θe calculation unit 27 by the αβ axis voltage command conversion unit 31. Next, the αβ-axis voltage command Vαβ is converted into an MCS-axis voltage command by the MCS-axis voltage command conversion unit 32 and input to the PWM signal generating means 33.

  The PWM signal generation means 33 generates the switching signals Mp, Cp, Sp, Mn, Cn, Sn of the switching elements 6a to 6f of the inverter circuit 5 as PWM signals from the MCS axis voltage command of the voltage coordinate conversion unit 22. . Based on this PWM signal, the switching elements 6 a to 6 f in the inverter circuit 5 are turned on and off, and the DC voltage of the rectifier circuit 2 is converted into three-phase AC and applied to the motor 7. The subscript “p” in the PWM signal indicates that it is for the upper arm switching element, and the subscript “n” indicates that it is for the lower arm switching element. M, S, and C indicate switching elements corresponding to terminals to which the motor 7 is connected. That is, the switching signal “Mp” is a driving signal for the switching element 6a.

By the operation as described above, the motor two-phase currents iM and iS are obtained using the shunt current of the inverter circuit 5, and further, the torque current component iq and the excitation current component id are obtained, and the switching elements 6a to 6 of the inverter circuit 5 are obtained. By performing PWM control on 6f, the motor 7 can be controlled without using the rotor magnetic pole position sensor signal.
Next, the structure of the motor 7 driven by the motor drive control device as described above and suitable for automatic production in which winding is performed in a state where the rotor and the stator are combined will be described with reference to FIG.

FIG. 3 is a structural diagram of the stator and rotor of the motor according to the first embodiment. 3A shows the stator and rotor components before coil winding, and FIG. 3B shows the stator and rotor components after coil winding.
In FIG. 3A, an insulating cover 40 is a cover that insulates between the 16-slot teeth 43 and the winding 8 (not shown). The magnet rotor 9 is a rotor without a back yoke using a four-pole polar anisotropic plastic magnet. This magnet rotor 9 is formed by integrally forming a rotor shaft 91 and then magnetizing it. The magnet rotor 9 and the rotor shaft 91 constitute a rotor shaft ASSY 45.

  In FIG. 3B, the stator teeth 44 after coil winding are obtained by inserting the rotor shaft ASSY 45 into the teeth 43, then inserting the insulating cover 40, and then winding the winding 8 (magnet wire). It is. By combining the stator core 44 after the coil winding with the stator core back 46, a magnetic path is formed, and the stator and the rotor are completed. The motor 7 is configured by combining the stator 50 and the rotor shaft ASSY 45 with a bearing 48 (see FIG. 4) and a motor frame 47 (see FIG. 4).

  Thus, since the winding is performed in a state where the rotor and the stator are combined, a motor structure with a small amount of copper and suitable for automatic production is obtained, and driven by the motor drive control device described above. Thus, a configuration in which a sensor or the like for detecting the magnetic pole position of the rotor is not provided can be provided. Next, the structure of the ventilation fan driven by the motor 7 will be described with reference to FIG.

  FIG. 4 is a diagram schematically showing a cross section of the ventilation fan according to the first embodiment. In FIG. 4, the ventilation fan 100 includes a motor 7, a metal casing 101, a sirocco fan 102, a ventilation fan grill 103, and a metal electrical product BOX 104. The ventilation fan 100 is attached to the ceiling wall 200. Further, the rotor shaft 91 of the motor 7 is connected to the sirocco fan 102 and is driven to rotate by the motor 7. The electrical product BOX 104 is moisture-proofed with a resin such as urethane, and incorporates an electronic circuit of a motor drive control device. Thereby, the ventilation fan 100 can be installed in a high humidity environment such as a bathroom.

  Thus, by adopting a configuration in which the sirocco fan 102 is rotationally driven by the motor 7 driven by the motor drive control device described above, the rotor is compared with the same stator structure as the two-phase induction motor manufactured in the conventional manufacturing equipment. Since the synchronous motor can be realized by exchanging the motor frame 47, the motor frame 47 can be shared and standardized. Therefore, there is no need for a new investment for the manufacturing equipment of the motor frame 47, and the manufacturing cost of the motor 7 can be reduced. Furthermore, the mounting structure of the ventilation fan 200 using the motor 7 can be the same as that using a conventional induction motor, and there is no need for additional mounting structure parts, which is inexpensive and energy-saving. A product using a high synchronous motor can be manufactured.

  As described above, in the first embodiment, based on the current flowing through the winding 8 of the motor 7, the inverter circuit 5 is PWM-controlled and the motor 7 is synchronously operated to detect the magnetic pole position of the rotor. The motor 7 that is a two-phase synchronous motor can be operated without providing a sensor or the like.

  In addition, since the motor 7 which is a two-phase synchronous motor can be operated without providing a sensor or the like for detecting the magnetic pole position of the rotor, in the automated production facility for a two-phase induction motor whose capital investment has been recovered. By using the rotor of the induction motor as a magnet rotor, a synchronous motor can be produced, and a synchronous motor with extremely high productivity that can be produced simultaneously with the induction motor can be obtained.

  Further, since there is no need to provide a sensor or the like for detecting the magnetic pole position of the rotor, disassembly / classification factors during recycling are reduced, and recyclability can be improved.

  Further, since it is not necessary to provide a sensor or the like for detecting the magnetic pole position of the rotor, it is not necessary to separately perform moisture-proof processing such as a sensor circuit even when the ventilation fan 100 is installed in a humid environment such as a bathroom. . Further, the motor other than the magnet rotor 9 can be manufactured by the same manufacturing equipment as the conventional induction motor, and a motor and its drive control apparatus applicable to a high-humidity ventilation fan can be obtained.

  A sensor or the like for detecting the magnetic pole position of the rotor is usually realized by mounting a sensor element using a compound semiconductor such as gallium arsenide or indium antimony on an electronic circuit board. By adopting a configuration in which a sensor or the like for detecting the magnetic pole position of the rotor is not provided as in this embodiment, disassembly / classification elements during recycling are reduced, and recyclability as a ventilation fan and a motor is improved.

Embodiment 2. FIG.
In the motor drive control device according to the second embodiment, the configuration of the rectifier circuit 2 is a voltage doubler rectifier circuit. The configuration of the motor 7 is the same as that in the above embodiment.

  FIG. 5 is a circuit diagram of a motor and a motor drive control device according to the second embodiment. In FIG. 5, the motor drive control device includes a rectifier circuit 2, an inverter circuit 5, a current detection means 11, a voltage detection means 13, and a sensorless control / midpoint voltage control means 14. The operation of the motor 7 driven by the supplied power is controlled.

  The rectifier circuit 2 in the present embodiment is a voltage doubler rectifier circuit, and converts the AC voltage of the commercial power source 1 into a DC voltage. For example, AC100V converts to DC280V. The rectifier circuit 2 is configured by connecting two rectifier diodes 3a and 3b. Furthermore, it is smoothed by the electrolytic capacitors 4a and 4b.

  The inverter circuit 5 receives the DC voltage output rectified by the rectifier circuit 2, performs PWM control by the operation of a sensorless control means described later, and converts the input DC voltage into a three-phase AC having an arbitrary voltage and an arbitrary frequency. . The inverter circuit 5 is configured by bridge-connecting switching elements 6a to 6d such as FETs. Each switching element 6a to 6d includes a high-speed diode in parallel in the reverse current direction. The built-in high-speed diode functions to flow a reflux current when the switching elements 6a to 6d are turned off. Furthermore, the inverter circuit 5 is provided with a shunt resistor 12 that converts the current of each arm of the switching element 6 into a voltage.

  The current detection means 11 amplifies and level-shifts the current of each arm of the inverter circuit 5 converted into a voltage by the shunt resistors 12a and 12b of the inverter circuit 5, and sends each arm current to the sensorless control / midpoint voltage control means 14. Output.

  The voltage detection means 13 shifts the level of the midpoint voltage of the electrolytic capacitors 4a, 4b and outputs it to the sensorless control / midpoint voltage control means 14.

The sensorless control / middle point voltage control means 14 performs PWM (Pulse Width Modulation) by determining the switching time of the switching element 6 of the inverter circuit 5 from the motor arm current obtained from the current detection means 11. By applying a voltage to each winding 8 of the motor 7 and controlling the winding current of the winding 8, a rotating magnetic field synchronized with the magnet rotor 9 is generated and the motor 7 is driven and controlled.
Further, the sensorless control / midpoint voltage control means 14 performs control so that the voltage at the midpoint between the electrolytic capacitors 4a and 4b obtained from the voltage detection means 13 is balanced and becomes 1/2 of the whole. Specifically, the M-phase and S-phase current balance is controlled by PWM control of the switching elements 6a to 6d so that the midpoint potential is balanced.

  In addition, the other structure and operation | movement in this Embodiment 2 are the same as that of the said Embodiment 1 (refer FIGS. 2-4).

As described above, in the second embodiment, in addition to the effect of the first embodiment, since the voltage doubler rectifier circuit is used for the rectifier circuit 2, the winding of the motor 7 is compared with the configuration of the first embodiment. 8 can be increased, and the induced voltage constant of the motor can be increased with respect to the configuration of the first embodiment when compared at the same axis output.
As a result, the winding current flowing through the motor 7 at the same load point can be reduced, and the copper loss in the winding 8 and the conduction loss of the switching element 6 of the inverter circuit 5 can be reduced. And a motor drive control device is obtained.

  In addition, since the number of switching elements 6 in the inverter circuit 5 is reduced from six in the first embodiment to four, it is possible to reduce the conduction loss of the switching element 6 at a lower cost than in the first embodiment. The drive control device is obtained.

Embodiment 3 FIG.
FIG. 6 is a diagram schematically showing the structure of the stator according to the third embodiment. 6, the stator according to the third embodiment includes a stator core 60 in which the stator teeth and the core back are integrated, a winding 8 wound between slots formed on the inner periphery of the stator core 60, and this winding. The lead wire 81 is connected to the end of the wire 8 and connects the winding 8 and the inverter circuit 5. The configuration other than the stator is the same as that of the first or second embodiment.

  The stator in the third embodiment shown in FIG. 6 constitutes the stator by inserting a bundle of windings 8 into a slot with respect to the integral stator core 60, so that compared with the first or second embodiment, After the stator is completed, the magnet rotor 9 can be inserted.

Here, the problem of control of a synchronous motor that requires a conventional magnetic pole position detection sensor (hereinafter also referred to as “sensor”) will be described. As shown in FIG. 6, when a stator is formed by inserting a bundle of windings 8 into a slot, the coil ends of the windings 8 greatly protrude from both sides of the stator core 60. Usually, the width of the magnet rotor 9 necessary for generating torque may be substantially the same as that of the stator core 60.
However, since the coil end is large, when the magnetic pole position detection sensor is disposed, it must be disposed at a position far from the stator core 60 by the width of the coil end. Since it weakens in proportion to the first power to the second power, the magnet length is extended to the sensor side or a separate magnet for the sensor is required. For this reason, it is necessary to increase the number of magnets that do not contribute to the torque by the height of the coil end or to provide separate parts, which increases the motor cost. Although it is conceivable to arrange the sensor side inside the coil end, a leakage magnetic flux is generated at the coil end. In this case, the sensor output fluctuates in proportion to the winding current, and the detection performance of the magnetic pole position is reduced. Reliability is impaired.
For this reason, in a two-phase synchronous motor using a manufacturing method in which the magnet rotor 9 is inserted later, there are many problems to incorporate the sensor in the motor.

  In the third embodiment, the motor drive control device described in the first or second embodiment is used to control the drive of the motor. Therefore, a magnetic pole position sensor in the motor is not required, and as shown in FIG. A stator in which the coil end protrudes greatly from both sides of the core can be used. For this reason, a low-cost and highly reliable motor, a motor drive control device, and a ventilation fan using the same are obtained.

Embodiment 4 FIG.
In the first to third embodiments, the sensorless control means 10 performs PWM control using the shunt current of each arm detected by the shunt resistors 12 a, 12 b, 12 c of the inverter circuit 5, and controls each winding 8 of the motor 7. By controlling the winding current, a rotating magnetic field synchronized with the magnet rotor 9 is generated and the motor 7 is driven and controlled, but voltage phase control is performed according to the induced voltage induced in each winding 8 of the motor 7, It goes without saying that the same effect can be obtained even when the motor 7 is operated synchronously.

Embodiment 5 FIG.
FIG. 7 is a diagram illustrating a configuration of an air conditioner according to Embodiment 5. In FIG. In FIG. 7, the air conditioner in the present embodiment includes an outdoor unit 310 and an indoor unit 320. The outdoor unit 310 is connected to a refrigerant circuit (not shown) and forms a refrigeration cycle, and heat (not shown). A blower 312 for an outdoor unit that blows the exchange is provided. The refrigerant compressor 311 and the outdoor unit blower 312 are driven by the motor 7 controlled by the motor drive control device of the first to fourth embodiments described above. Needless to say, even if the motor 7 is operated with such a configuration, the same effects as those of the first to fourth embodiments can be obtained.

Embodiment 6 FIG.
FIG. 8 is a diagram showing the configuration of the refrigerator according to the sixth embodiment. As shown in FIG. 8, a refrigerator 400 is connected to a refrigerant circuit (not shown) and constitutes a refrigeration cycle. A refrigerator 400, a cooler 403 provided in a cooling chamber 402, cooler 403 A cooler circulation blower 404 for sending to a room or the like is provided. The refrigerant compressor 401 and the cool air circulation fan 404 are driven by the motor 7 controlled by the motor drive control device of the first to fourth embodiments described above. Needless to say, even if the motor 7 is operated with such a configuration, the same effects as those of the first to fourth embodiments can be obtained.

  Even if the target load driven by the motor 7 is applied to a liquid circulation pump or a well pump and is operated by the motor drive control device of the above-described first to fourth embodiments, Needless to say, similar effects can be obtained.

  DESCRIPTION OF SYMBOLS 1 Commercial power supply, 2 Rectifier circuit, 3a Rectifier diode, 3b Rectifier diode, 3c Rectifier diode, 3d Rectifier diode, 4 Electrolytic capacitor, 4a Electrolytic capacitor, 4b Electrolytic capacitor, 5 Inverter circuit, 6 Switching element, 6a Switching element, 6b Switching Element, 6c switching element, 6d switching element, 6e switching element, 6f switching element, 7 motor, 8 windings, 8a main winding, 8b auxiliary winding, 9 magnet rotor, 10 sensorless control means, 11 current detection means, 12 Shunt resistor, 12a Shunt resistor, 12b Shunt resistor, 12c Shunt resistor, 13 Voltage detection means, 14 Sensorless control / midpoint voltage control means, 20 Current coordinate conversion unit, 21 Current control unit, 22 Voltage coordinate change , 23 αβ axis current converter, 24 dq axis current converter, 25 slip compensator, 26 speed controller, 27 θe calculator, 28 current error calculator, 29 low pass filter, 30 current controller, 31 αβ axis voltage Command conversion unit, 32 MCS shaft voltage command conversion unit, 33 PWM signal generation means, 40 Insulation cover, 43 teeth, 44 stator teeth, 45 rotor shaft assembly, 46 stator core back, 47 motor frame, 48 bearing, 50 stator, 60 stator core 81 Lead wire, 91 Rotor shaft, 100 Ventilation fan, 101 Metal enclosure, 102 Sirocco fan, 103 Ventilation fan grille, 104 Electric box, 200 Ceiling wall, 310 Outdoor unit, 311 Refrigerant compressor, 312 Blower, 320 Indoor unit, 400 refrigerator, 40 Refrigerant compressor, 402 cooling chamber, 403 cooler, 404 blower, M main winding terminal, S auxiliary winding terminals, C common terminal.

Claims (1)

Detection means comprising a stator having a two-phase stator winding composed of a first winding and a second winding, and a rotor having a plurality of magnetic poles made of permanent magnets, and detecting a magnetic pole position of the rotor A method for manufacturing a synchronous motor that is controlled to operate synchronously,
Magnetizing the rotor to form a plurality of magnetic poles;
Insert the rotor tooth of the stator, combining the said and the stator rotor,
Then, an insulating cover that performs insulation between the stator teeth and the stator winding is inserted into the stator teeth,
Thereafter, the stator winding is wound, and the method for manufacturing a synchronous motor is provided.

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