JP5471933B2 - Rotor with magnet - Google Patents

Description

  The present invention relates to a rotor with a magnet that includes a rotor core including a magnet insertion hole, a gap forming hole continuous with the magnet insertion hole, and a magnet inserted into the magnet insertion hole.

  Conventionally, in a rotating electrical machine including a stator and a rotor, a permanent magnet type rotating electrical machine using a rotor with a magnet having a permanent magnet has been used as the rotor. The rotor with magnets prevents permanent magnets from falling out of the magnet insertion holes by inserting permanent magnets into the magnet insertion holes provided in the rotor core, filling the holes continuous with the magnet insertion holes and solidifying the resin. Has been done.

  For example, Patent Document 1 describes a rotor with a permanent magnet that includes a substantially cylindrical yoke and a permanent magnet. The yoke has a storage portion, stores the permanent magnet in the storage portion, and closes the storage portion with upper and bottom lids provided on both end surfaces of the yoke. Resin is injected between the storage portion and the permanent magnet, and the upper lid has a recess formed on the surface facing the permanent magnet. Since the resin flows into the concave portion when the resin is injected into the storage portion, the concave portion functions as a buffer, and the resin can be prevented from leaking to the outer peripheral surface of the yoke.

  On the other hand, Patent Document 2 describes a rotor including a soft magnetic rotor core, front and rear magnets inserted into the rotor core, and soft magnetic segments. The rotor core has a soft magnetic yoke portion and a magnetic salient pole portion projecting from the outer peripheral surface of the yoke portion toward the radial stator, and the front end and the rear end of the segment are at the side end surface of the tip portion of the magnetic salient pole portion. It is connected by a connection part. In addition, a nonmagnetic portion, which is a space partitioned into magnetic salient pole portions, segments, and permanent magnets, may be filled with resin or nonmagnetic metal.

JP 2009-77547 A JP 2009-124899 A

  In the case of the rotors described in Patent Documents 1 and 2, it is said that the storage portion and the nonmagnetic portion can be filled with resin. In the case of the rotor described in Patent Document 2, resin can be filled into a gap that is a non-magnetic portion that is continuous with the insertion portion of the permanent magnet. In this case, there is a possibility that the magnet can be fixed to the rotor by filling the resin. However, if the gap that is continuous with the magnet insertion part or the gap that is continuous with this gap is large, the resin may flow into the large gap when the resin is filled, which increases the amount of resin used and the cost of manufacturing the rotor. Causes it to rise. For this reason, in the rotor, realization of means capable of reducing the amount of resin used is desired. On the other hand, in order to improve the performance of the rotor, the rotor core is composed of a laminated steel plate obtained by laminating a plurality of steel plates.

  On the other hand, as a rotor capable of reducing the amount of resin used, a rotor is also considered in which the gap is partitioned by a sealing member formed in a plate shape or the like, and the resin is filled only in a small gap partitioned by the sealing member. . In this case, the seal member is abutted against the seal abutting portion provided on the inner surface of the hole forming the gap of the rotor core. However, when the rotor core is composed of laminated steel plates, there is a possibility that minute irregularities are generated on the side surfaces of the seal abutting portions due to the positional deviation between adjacent steel plates. For this reason, when the seal member is abutted against the seal abutting portion, a gap based on the unevenness of the seal abutting portion may occur at the contact portion between the seal abutting portion and the seal member. When this gap occurs, when resin is filled into a small gap, the resin leaks to the large gap side through the gap generated at the contact portion between the seal abutting portion and the seal member, and the amount of resin used May increase.

  An object of the present invention is to effectively reduce the amount of resin used in a rotor with magnets in a configuration in which a rotor core is formed of laminated steel plates.

Rotor with magnets according to the invention consists of a laminated steel plate, a magnet insertion hole, wherein a gap formed hole continuing to the magnet insertion holes, connecting by said magnet insertion hole and the gap forming holes are connected wherein the rotor core includes a gap forming holes for forming a hole, and a magnet is inserted into the magnet insertion holes, wherein the rotor core, the magnet insertion holes, or the space formation hole, or with the magnet insertion holes the connection of the void-formed holes, a seal abutment section provided in the gap formed hole side than the magnet end face, comprises a formed sealing abutment portion by the laminated steel plates, further, to the connecting hole It is opposed to the end surface of said magnet being inserted, and a seal member that is abutted on the seal abutment portion, in the sealing abutment portion, the uneven surface facing the sealing member, the uneven A coating resin material applied to fill the recess of the end faces of the magnet and the filled in a resin filling space provided between the seal member, and characterized in that it comprises a filling resin is solidified It is a rotor with a magnet.

  In the rotor with magnet according to the present invention, preferably, the seal abutting portion is provided on the side surface of the end portion of the gap forming hole that is connected to the magnet insertion hole.

  According to the rotor with a magnet of the present invention, in the configuration in which the rotor core is formed of laminated steel plates, the resin passes through the contact portion between the seal member and the seal abutting portion when the resin is filled into the resin filling space. The amount of resin used can be effectively reduced without leaking to the large gap portion side.

It is a fragmentary sectional view which shows a rotary electric machine provided with the rotor with a magnet of one example of embodiment of this invention. It is a figure which expands and shows a part of FIG. It is the A section enlarged view of FIG. It is a figure corresponding to Drawing 3 shown in the state before providing filling resin in the space for resin filling. It is a BB sectional view of Drawing 3 shown in the state where a seal board and an application resin material were separated. It is a figure corresponding to FIG. 5 for demonstrating the inconvenience in the comparative example which deviated from this invention.

  Hereinafter, embodiments according to the present invention will be described in detail with reference to the drawings. 1 to 5 show an example of an embodiment of the present invention.

  As shown in FIG. 1, a rotating electrical machine 10 including a rotor with magnets according to the present embodiment includes a stator 12 fixed to a motor case (not shown) and a rotatable rotor with magnets arranged to face the inside of the stator 12 in the radial direction ( Hereinafter, it is simply referred to as “rotor”) 14. Stator 12 includes a stator core, a plurality of teeth provided on an inner peripheral surface of the stator core so as to protrude in the radial direction, and a stator winding wound around the plurality of teeth. The plurality of stator windings are, for example, three-phase stator windings, and a rotating magnetic field is generated in the stator 12 when a three-phase alternating current is input from a power source via an inverter.

  The rotor 14 includes a rotor core 16 and a plurality of permanent magnets 18 provided on the rotor core 16. The rotor core 16 is used by being fixed to a rotating shaft (not shown), and is constituted by a laminated steel plate formed by laminating a plurality of steel plates. The rotor core 16 includes a plurality of magnet insertion holes 20 and gap formation holes 24 that are continuous with the respective magnet insertion holes 20. Two magnet insertion holes 20 are arranged at a portion near the outer periphery of the rotor core 16 and a plurality of sets are arranged at equal intervals in the circumferential direction. In each set, two magnet insertion holes 20 provided so as to extend in a straight line are arranged in a substantially V shape so as to spread toward the outside in the radial direction of the rotor core 16.

  On the other hand, the gap forming hole 24 is continuous with the inner end of the magnet insertion hole 20 in the radial direction (“radial direction” refers to the radial direction of the rotor core 16; the same shall apply hereinafter), and radially inward and circumferentially. It spreads in the direction. And the permanent magnet 18 is inserted in the magnet insertion hole 20, respectively, and it fixes with the filling resin mentioned later.

  The permanent magnet 18 is magnetized in the direction indicated by the arrow in FIG. 1 or in the direction opposite to the arrow. Further, the permanent magnets 18 inserted into the respective magnet insertion holes 20 are configured to generate a magnetic field having the same pole on the same side in the radial direction. Further, the air gap forming holes 24 formed in the rotor core 16 are provided in order to form the air gap portions K therein and to appropriately set the magnetic characteristics generated by the rotor 14. FIG. 1 shows only a part in the circumferential direction of the rotor 14 and the stator 12, and a plurality of configurations similar to the configuration shown in FIG. ing. In order to configure in this way, the magnetic poles of the N pole and the S pole are alternately arranged in the circumferential direction on the outer peripheral portion of the rotor 14.

  As shown in detail in FIGS. 2 to 4, the rotor core 16 is a connecting portion between the magnet insertion hole 20 and the gap forming hole 24, and the width direction of the one end face 30 with respect to the length direction of the permanent magnet 18 (FIG. 2). To the left and right directions in FIG. 4) including a protruding portion 32 made of a laminated steel plate located at one end.

  Further, in the present embodiment, in order to fix the permanent magnet 18 to the rotor core 16, the filling resin 36 configured by filling the both ends of the magnet insertion hole 20 with a molten resin and solidifying it is provided. For example, in FIGS. 2 and 3, the filling resin 36 is represented by a sand portion. For example, the filling resin 36 is composed of a thermosetting resin. In this case, after filling the rotor core 16 with the molten resin, the rotor core 16 is heated, the resin is cured and solidified, and then cooled to form the filled resin 36.

  In addition, in order to prevent the resin from flowing into the gap formation hole 24 when the magnet insertion hole 20 is filled with the molten resin, the gap formation hole 24 is provided even though the gap formation hole 24 is continuous with the magnet insertion hole 20. A seal plate 38 serving as a seal member is disposed on the inner side of 24 opposite to the magnet insertion hole 20. The seal plate 38 has a trapezoidal cross section and abuts two side surfaces against abutment portions 33 and 34 that are seal abutment portions located at two locations on the inner surface of the gap forming hole 24. That is, the abutting portions 33 and 34 are provided on the two side surfaces of the end portion on the side connected to the magnet insertion hole 20 in the gap forming hole 24. In this case, in the rotor core 16, the abutting portions 33 and 34 that abut the seal plate 38 are made of laminated steel plates, and therefore, the side surfaces of the abutting portions 33 and 34 are caused by positional deviations of a plurality of steel plates constituting the laminated steel plates. Concavities and convexities may occur on the surface. In the present embodiment, even when such unevenness occurs, the resin is prevented from leaking to the gap forming hole 24 side through the gap between the unevenness and the seal plate 38 when the molten resin is filled into the magnet insertion hole 20. In order to do so, a resin material is applied to each of the abutting portions 33 and 34.

  That is, as shown in detail in FIGS. 3 to 5, the rotor 14 includes a seal plate 38 that is a seal member, a coating resin material 40 (FIG. 5), and a filling resin 36. The seal plate 38 is configured in a flat plate shape, for example, with resin, nonmagnetic metal, or the like, and is disposed opposite to the one end face 30 of the permanent magnet 18 inserted into the magnet insertion hole 20. The seal plate 38 is not limited to a trapezoidal cross section, and can have various shapes. Further, as shown in FIG. 3, both side surfaces in the width direction of the seal plate 38 are abutted against the side surfaces of the abutting portions 33 and 34 provided on the inner surface of the gap forming hole 24.

  Moreover, as shown in FIG. 5, the uneven | corrugated surface 44 based on the positional offset of several steel plates 42 is provided in the side surface facing the sealing plate 38 in the side surface of the butting parts 33 and 34 comprised with a laminated steel plate. Yes. The coated resin material 40 is applied to the concavo-convex surface 44 so as to fill the concave portion of the concavo-convex surface 44. Therefore, one side (the left side in FIG. 5) of the coated resin material 40 has a shape along the uneven surface 44. In this state, the seal plate 38 abuts against the side surfaces of the abutment portions 33 and 34 via the coating resin material 40. For example, the coating resin material 40 is a resin adhesive containing a silicone resin or the like. In this case, the sealing plate 38 is adhesively bonded to the abutting portions 33 and 34 by the coating resin material 40. The application resin material 40 is not limited to such a resin adhesive, and various resin materials can be used. Moreover, if the side surface which abuts the sealing plate 38 of the abutting portions 33 and 34 is included, the coating resin material can be applied to other portions of the rotor core 16. 3 to 5, the abutting portions 33 and 34 are configured by a part of the inner surface of the gap forming hole 24. However, the seal abutting portion that abuts the seal plate 38 is a side surface that is located on a side surface of the magnet insertion hole that is out of one end in the longitudinal direction of the permanent magnet, or a connection portion between the magnet insertion hole and the gap forming hole, For example, it can also be set as the side surface of the protrusion part 22 etc., and the application | coating resin material 40 can also be apply | coated to the side surface which abuts the seal plate 38 of this seal | sticker contact part. In the example shown in FIG. 1, the seal plate 38 is provided only in one gap forming hole 24 among the two gap forming holes 24 connected to each set of magnet insertion holes. 24 can be provided with a sealing plate 38, and a coating resin material can be provided between the sealing plate 38 and the side surface of each gap forming hole 24 where the sealing plate 38 abuts.

  Further, as shown in FIG. 4, the rotor 14 includes an end surface 30 of the permanent magnet 18, a side surface of the connecting portion of the magnet insertion hole 20 such as the projecting portion 32 and the gap forming hole 24, and a side surface of the seal plate 38. An enclosed resin filling space 46 is provided. That is, the resin filling space 46 is provided between the one end face 30 of the permanent magnet 18 and the side face of the seal plate 38. Further, as shown in FIG. 3, the resin filling space 46 is filled with resin and solidified to provide the filling resin 36. As shown in FIG. 2, the filling resin 36 fills the resin filling space provided at the other end in the length direction of the magnet insertion hole 20 (upper end in FIG. 2). The permanent magnet 18 is prevented from falling off from the magnet insertion hole 20.

  According to such a rotor 14, since the coating resin material 40 is applied so as to fill the concave portions in the concave and convex surfaces 44 on the side surfaces of the abutting portions 33 and 34 that are in contact with the seal plate 38, the rotor core 16 is made of laminated steel plates. In the configuration to be configured, when the molten resin is filled into the resin filling space 46 existing around the end of the permanent magnet 18 with the seal plate 38 abutting against the uneven surface 44, the molten resin is provided on the uneven surface 44. Through the contact portion between the sealing plate 38 and the sealing plate 38, there is no leakage to the large gap K side inside the gap forming hole 24. For this reason, the amount of resin used in the rotor 14 can be effectively reduced.

  FIG. 6 is a diagram corresponding to FIG. 5 for explaining inconveniences in a comparative example that is out of the present invention. In this comparative example, in the same configuration as that of the present embodiment, the abutting portions provided at two positions which are the end portions of the air gap forming hole and located at the peripheral portion of the one end surface in the length direction of the permanent magnet The coated resin material 40 (see FIG. 5) is not applied to any of the side surfaces against which the 33 and 34 sealing plates 38 are abutted. Therefore, the sealing plate 38 is directly abutted against the abutting portions 33 and 34 without the application resin material 40 interposed therebetween. In the case of such a comparative example, based on the positional deviation between the plurality of steel plates 42 constituting the laminated steel plate, a black background is shown in FIG. A gap 48 filled with is formed. For this reason, when the resin filling space 46 (see FIG. 4) is filled with resin, the resin may leak through the gap 48 to the gap K (see FIG. 4), which is a wide space. According to the present embodiment, since such a gap is not formed by the coated resin material 40 as described above, resin leakage to the gap K side can be prevented, and the amount of resin used in the rotor 14 can be effectively reduced. For this reason, the manufacturing cost of the rotor 14 can be reduced.

  In the rotor 14, the arrangement and shape of the magnet insertion holes 20 and the gap formation holes 24 are not limited to the examples shown in FIGS. 1 to 4 above, and various arrangements may be made with respect to the magnet insertion holes and the gap formation holes. In addition, the present invention can be implemented with a rotor adopting the shape. Further, in the above description, the case where the rotor 14 is an inner rotor disposed to face the radially inner side of the stator 12 has been described. However, the present invention is not limited to such a configuration. For example, the present invention can also be implemented in an outer rotor in which the rotor is disposed to face the outer side in the radial direction of the stator.

  DESCRIPTION OF SYMBOLS 10 Rotating electrical machine, 12 Stator, 14 Rotor with magnet, 16 Rotor core, 18 Permanent magnet, 20 Magnet insertion hole, 24 Space | gap formation hole, 30 One end surface, 32 Projection part, 33, 34 Abutting part, 36 Filling resin, 38 Seal Plate, 40 coated resin material, 42 steel plate, 44 uneven surface, 46 resin filling space, 48 gap.

Claims (3)

Is composed of laminated steel plates, and the magnet insertion holes, wherein a gap formed hole continuing to the magnet insertion hole, and a gap forming holes for forming the connecting hole by said magnet insertion hole and the gap forming holes are connected Including rotor core,
A magnet inserted into the magnet insertion hole,
The rotor core is
The magnet insertion holes, or the space formed holes or connecting portion between the magnet insertion hole and the gap forming hole, and a sealing abutment portion provided in the gap formed hole side than the magnet end face, wherein Including a seal abutment part composed of laminated steel sheets,
further,
Wherein is inserted into the coupling hole is opposed to the end surface of the magnet, and a seal member that is abutted on the seal abutting portion,
In the sealing abutment portion, the uneven surface facing the sealing member, a coating resin material applied to fill the concave portion of the uneven surface,
The filled in a resin filling space provided between the end face of the magnet and the sealing member, a rotor with magnets, characterized in that it comprises a filling resin is solidified. The rotor with magnet according to claim 1,
Said seal abutting portion, in the space forming hole, said rotor with magnets, characterized in that provided on the side surface of the end on the side to be connected to the magnet insertion holes. In the rotor with magnet according to claim 1 or 2,
The rotor with magnet, wherein the sealing member is a member different from the steel plate forming the laminated steel plate, and is formed of a resin or a nonmagnetic metal.

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