JP6545387B2 - Conscious pole rotor, motor and air conditioner - Google Patents

Description

  BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a consistent pole type rotor, a motor and an air conditioner.

  Conventionally, in order to improve the energy saving property of the air conditioner, a rare earth magnet having a high energy density such as a neodymium sintered magnet is generally used as a permanent magnet of a motor mounted on a compressor of the air conditioner. In addition, a motor using a neodymium sintered magnet has been developed for a fan of an air conditioner.

  Such permanent magnets are expensive because they contain valuable rare earth elements. Therefore, there is a strong demand for reducing the usage amount and processing cost of permanent magnets to reduce the cost.

  Permanent magnets are generally machined into block-shaped masses into specified shapes. Therefore, as the number of permanent magnets used in the motor increases, the processing cost increases.

  As a method of reducing the number of permanent magnets used in the motor, there is a method of configuring the rotor with so-called contingent poles. In the rotor of the consistent pole type disclosed in Patent Document 1, the magnet magnetic poles by permanent magnets and the salient poles formed on the core material regardless of the permanent magnets are alternately arranged in the circumferential direction. Therefore, the number of magnet poles and the number of salient poles are both half the number of poles. Further, the magnet poles having half the number of poles have the same polarity, and the salient poles having half the number of poles have a polarity different from that of the magnet poles. As described above, in the case of a consistent pole type rotor, the number of permanent magnets is half that of a normal one. However, in the consistent pole type rotor, the inductance differs between the magnet magnetic pole and the salient pole, and there is a problem that vibration and noise become large due to the unbalance of the inductance.

  With respect to this problem, in Patent Document 1, the asymmetry of the inductance is improved and vibration noise is reduced by devising the flux barrier shape at both ends of the permanent magnet in the consistent pole type rotor. The flux barrier is an air gap formed at both ends in the circumferential direction of the magnet insertion hole, and is formed in a state in which the permanent magnet is disposed in the magnet insertion hole.

JP 2012-244783

  Compared to a conventional IPM rotor, which uses a number of permanent magnets corresponding to the total number of poles, the consistent pole rotor has half the number of magnets. Therefore, in the case of the consistent pole type rotor, the circumferential width of the bridge existing between the adjacent permanent magnets is relatively expanded, and the bridge is less likely to saturate the magnetic flux. Therefore, the magnetic resistance due to the bridge is smaller than that of a conventional IPM rotor. Thus, in the consistent pole type rotor, leakage flux generated at one of the permanent magnet's N pole or S pole flows through the bridge to the other N pole or S pole of the permanent magnet. And cause a reduction in induced voltage due to magnetic flux leakage.

  In order to solve such a problem, by reducing the thickness in the radial direction of the thin bridge formed between the flux barrier and the outer peripheral surface of the rotor core, the magnetic resistance of the thin bridge is increased, and the magnetic flux is increased. Leakage can be reduced. However, in the conventional consistent pole type rotor shown in Patent Document 1, since the rotor core is manufactured by the core press, there is a limit in reducing the thickness of the thin bridge so as to facilitate magnetic flux saturation. In a small motor, it is difficult to reduce the thickness of the thin bridge, so there is a problem that the magnetic flux leakage rate becomes large and the efficiency is reduced.

  The present invention has been made in view of the above, and it is an object of the present invention to obtain a consistent pole type rotor that improves efficiency by suppressing a decrease in magnetic force due to magnetic flux leakage while reducing manufacturing costs. .

  In order to solve the problems described above and to achieve the object, a consistent pole type rotor according to the present invention comprises a permanent magnet and a first protrusion having a first protrusion and a second protrusion on the outer peripheral surface. And a core, the first core having a recess formed between the first protrusion and the second protrusion on the outer peripheral surface, and an insertion portion into which the permanent magnet is inserted and which has an opening communicating with the recess A hole, a first end formed between the first protrusion and the recess, and a second end formed between the recess and the opening.

  The consistent pole type rotor according to the present invention has an effect that the efficiency can be improved by suppressing the decrease of the magnetic force due to the magnetic flux leakage while reducing the manufacturing cost.

Side cross-sectional view of motor according to Embodiment 1 Side cross-sectional view of the mold stator shown in FIG. 1 Side cross-sectional view showing a state in which the rotor is inserted into the molded stator shown in FIG. 2 Side cross-sectional view of the bracket shown in FIG. 1 A block diagram of a stator core constructed of a plurality of divided core parts and developed in a band shape The figure which shows the state which bend | folded the expanded stator core shown in FIG. 5, and was comprised cyclically | annularly Cross section of a rotor in which all magnetic poles are composed of permanent magnets A partial enlarged view of the rotor shown in FIG. 7 Cross section of a typical continuous pole rotor A partial enlarged view of the rotor shown in FIG. 9 First cross-sectional view of a consistent pole type rotor according to Embodiment 1 Second cross-sectional view of the consistent pole rotor according to the first embodiment FIG. 12 is a perspective view of a rotor core configured by alternately stacking the first core shown in FIG. 11 and the second core shown in FIG. 12 in the axial direction. Side view of rotor core shown in FIG. 13 The first core block shown in FIG. 11 in which a plurality of first cores are stacked in the axial direction, and the second core block shown in FIG. 12 in which the plurality of second cores are stacked in the axial direction are alternately arranged in the axial direction View of a rotor core constructed by laminating on Side view of rotor core shown in FIG. A first core block in which a plurality of first cores shown in FIG. 11 are stacked in the axial direction and a second core block in which a plurality of second cores shown in FIG. 12 are stacked in the axial direction are stacked in the axial direction View of the rotor core configured Side view of the rotor core shown in FIG. The figure which shows the state which applied resin to the rotor core shown in FIG. 13, FIG. 15, or FIG. A partial enlarged view of the rotor core shown in FIG. 19 The figure which shows the state which formed the notch part in the rotor core shown in FIG. 13, FIG. 15, or FIG. A partial enlarged view of the rotor core shown in FIG. 21 The figure which shows the state by which the opening part of the rotor core shown in FIG. 22, the 1st notch part, and the 2nd notch part were covered by resin. A partial enlarged view of the rotor core shown in FIG. A diagram for explaining a step formed on an outer peripheral surface of a rotor core shown in FIG. The figure which shows the state by which the corner between the resin outer peripheral surface of blockade resin shown in FIG. 25 and the circumferential direction end face of blockage resin was formed in R shape or chamfering shape The figure which shows the example which formed the resin outer peripheral surface of obstruction | occlusion resin so that the level difference shown in FIG. 25 might be eliminated. The figure which shows the metal mold which suppresses the outer peripheral surface of the rotor core which concerns on this Embodiment from the radial direction. A perspective view of a rotor after resin is applied to a rotor core shown in FIG. 13, FIG. 15 or FIG. Side view of the rotor shown in FIG. The figure which shows an example of a structure of the air conditioner which concerns on Embodiment 2.

  Hereinafter, a consistent pole type rotor, a motor and an air conditioner according to an embodiment of the present invention will be described in detail based on the drawings. The present invention is not limited by the embodiment.

Embodiment 1
FIG. 1 is a side cross-sectional view of the motor according to the first embodiment. The motor 100 shown in FIG. 1 includes a mold stator 10, a rotor 20, and a metal bracket 30 attached to one axial end of the mold stator 10. The motor 100 is a brushless DC motor that has a permanent magnet on a rotor 20 and is driven by an inverter. The rotor 20 is of the internal magnet type and of the consistent pole type.

  The mold stator 10 includes a stator 40 and a mold resin 50 covering the stator 40. The axial direction of the mold stator 10 coincides with the axial direction of the shaft 23 of the rotor 20. The details will be sequentially described, but in FIG. 1, as a component of the stator 40, a stator core 41, a coil 42 wound around the stator core 41, and an insulating portion provided in the stator core 41 43 and a neutral point terminal 44b provided in the insulating portion 43 are shown.

  Further, in FIG. 1, the substrate 45 attached to the insulating portion 43, the lead wire lead-out component 46 assembled to the substrate 45, the lead wire 47 lead out from the lead wire lead-out component 46, and the substrate 45 are mounted. An IC (Integrated Circuit) 49 a and a Hall IC 49 b mounted on the surface of the substrate 45 on the side of the rotor 20 are shown.

  Further, the rotor 20 is mounted on the shaft assembly 27, the resin portion 24 which integrates the rotor 20 main body and the shaft assembly 27, and the load side which is attached to the shaft 23 and supported by the bearing support 11 of the molded stator 10. A rolling bearing 21 a and an anti-load side rolling bearing 21 b attached to the shaft 23 and supported by the bracket 30 are provided. The load side 110 represents the end face side where the shaft 23 protrudes out of both end faces of the motor 100, and the anti-load side 120 represents the end face side where the bracket 30 is provided.

  The shaft assembly 27 includes an insulating sleeve 26 consisting of a pair of insulating sleeves 26-1 and 26-2, and the insulating sleeve 26 is disposed between the non-load side rolling bearing 21b and the shaft 23.

  FIG. 2 is a side cross-sectional view of the mold stator shown in FIG. In FIG. 2, the same components as in FIG. 1 are assigned the same reference numerals. In the mold stator 10, an opening 10b is formed at one axial end of the mold stator 10, and the rotor 20 is inserted into the opening 10b. A hole 11a larger than the diameter of the shaft assembly 27 of the rotor 20 shown in FIG. 1 is formed at the axial end of the molded stator 10 to which the load-side rolling bearing 21a of the rotor 20 inserted into the opening 10b is fitted. Is open. Other configurations of the mold stator 10 will be described later.

  FIG. 3 is a side sectional view showing a state in which the rotor is inserted into the mold stator shown in FIG. In FIG. 3, the same components as in FIG. 1 are denoted by the same reference numerals. The rotor 20 inserted from the opening 10b of the molded stator 10 shown in FIG. 2 is arranged such that the load side of the shaft assembly 27 is pulled out of the molded stator 10 through the hole 11a shown in FIG. Ru. At this time, the load-side rolling bearing 21 a attached to the shaft 23 is pushed until it abuts on the bearing support portion 11 of the molded stator 10, and is supported by the bearing support portion 11. The bearing support 11 is an axial end of the mold stator 10 and is provided on the opposite side of the opening 10 b.

  On the non-load side of the shaft assembly 27, an anti-load side rolling bearing 21b is attached. The mounting of the anti-load side rolling bearing 21b is generally by press-fitting. Although details will be described later, an insulating sleeve 26 integrally formed with the shaft 23 is provided between the non-load side rolling bearing 21 b and the non-load side of the shaft 23.

  FIG. 4 is a side sectional view of the bracket shown in FIG. The bracket 30 closes the opening 10 b of the molded stator 10 and supports the anti-load side rolling bearing 21 b, and is press-fitted to the molded stator 10. The bracket 30 includes a bearing support portion 30a and a press-fit portion 30b integrally formed with the bearing support portion 30a. The bearing support portion 30a supports the anti-load side rolling bearing 21b. The press-fit portion 30b has a ring shape.

  The bracket 30 is attached to the mold stator 10 by press-fitting the press-fit portion 30 b to the opening 10 b side of the inner peripheral portion 10 a of the mold stator 10. The outer diameter of the press-fit portion 30 b is larger than the inner diameter of the inner circumferential portion 10 a of the mold stator 10 by the press-fit margin. The bracket 30 is made of a conductive metal, and is formed of, for example, a galvanized steel sheet. However, the bracket 30 can also be formed from materials other than galvanized steel. As a material of the bracket 30, an aluminum alloy, an austenitic stainless alloy, a copper alloy, cast iron, steel or an iron alloy can be exemplified.

  The configuration of the mold stator 10 will be described below. The mold stator 10 shown in FIG. 2 includes a stator 40 and a mold resin 50 for molding. As the mold resin 50, unsaturated polyester resin is used. In particular, a mass clay-like thermosetting resin (Bulk Molding Compound: BMC) in which various additives are added to unsaturated polyester resin is desirable as a motor. For example, thermoplastic resins such as polybutylene terephthalate (PBT) and poly phenylene sulfide (PPS) are more advantageous because runners during molding can be recycled.

  However, unsaturated polyester resin and BMC have linear expansion coefficients close to that of iron-based materials such as stator core 41, load side rolling bearing 21a, and anti-load side rolling bearing 21b, and their thermal contraction rate is 1 of thermoplastic resin. By being 10/10 or less, it is excellent in obtaining a dimensional accuracy.

  In addition, when the outer shell of the motor 100 is formed of unsaturated polyester resin and BMC as compared with the case where the outer shell of the motor 100 is formed of metal such as iron and aluminum, the heat dissipation is excellent. When the outer shell of the motor 100 is formed of metal, the metal forming the outer shell of the motor 100 is separated from the coil 42 and the substrate 45 due to the insulation problem. On the other hand, since unsaturated polyester resin and BMC are insulators, there is no insulation problem even if the coil 42 and the substrate 45 are covered, and the thermal conductivity is also high, so the heat dissipation is excellent, and the high output of the motor 100 Contribute to

  The load side rolling bearing 21 a is supported by the bearing support 11 formed of the mold resin 50, and the anti-load side rolling bearing 21 b and the bracket 30 are supported by the inner circumferential portion 10 a formed of the mold resin 50. Therefore, when the dimensional accuracy of the mold resin 50 is poor, the axial center of the rotor 20 and the axial center of the stator 40 are displaced, which causes vibration and noise. However, the use of unsaturated polyester resin and BMC having a small heat shrinkage ratio makes it easy to ensure dimensional accuracy after molding.

  In addition, when a resin having a large linear expansion coefficient is used, rattling of the bearing may be a problem when the motor 100 becomes high temperature. The unsaturated polyester resin and BMC have a linear expansion coefficient close to that of an iron-based material such as the stator core 41, the load side rolling bearing 21a and the anti-load side rolling bearing 21b, and therefore rotate regardless of the temperature of the motor 100. Deviation between the axis of the child 20 and the axis of the stator 40 can be suppressed.

  In addition, since the unsaturated polyester resin and BMC restrain the stator 40 when it is cured, it is possible to suppress the deformation of the stator 40 accompanying the excitation force of the motor 100, and to suppress the vibration and the noise.

  FIG. 5 is a structural view of a stator core which is constituted by a plurality of divided core parts and developed in a band shape. In the stator core 41 shown in FIG. 5, the plurality of divided core portions 400 are arranged such that each of the plurality of divided core portions 400 contacts another adjacent one of the plurality of divided core portions 400. . Each of the plurality of split core portions 400 has a back yoke 401 and teeth 402 protruding from the back yoke 401. Thin portions 403 connecting the back yokes 401 are provided between the adjacent back yokes 401.

  FIG. 6 is a view showing a state in which the unfolded stator core shown in FIG. 5 is bent to form an annular shape. After the coil 42 of FIG. 1 is applied to each of the plurality of teeth 402 shown in FIG. 5, the annular stator core 41 shown in FIG. It is formed.

  As shown in FIGS. 5 and 6, the stator core 41 configured of the plurality of divided core portions 400 can wind the coil 42 in a band-like expanded state, so high density of the coil 42 is possible, which is highly efficient. It is effective for However, since the split core portion 400 is connected by the thin portion 403, the rigidity of the stator core 41 when formed in an annular shape is weak, and the one having a large excitation force like the consistent pole type motor 100 is not suitable. It is effective to mold the stator core 41 with saturated polyester resin, that is, to cover the stator core 41 with unsaturated polyester resin.

  The stator core 41 formed of a plurality of divided core portions 400 has an uneven surface at the end of the back yoke 401 as well as the structure in which the adjacent back yokes 401 are connected by the thin portion 403 as shown in FIG. It may have a structure in which the dowels are connected to each other by forming a shape-like dowel, or a structure in which a plurality of back yokes 401 separated from each other are fixed by welding or fitting. By covering the stator core thus configured with unsaturated polyester resin, vibration and noise can be reduced.

  Thus, it is desirable to completely cover the stator core with unsaturated polyester resin, but as shown in FIG. 2, the thickness from the outer peripheral portion 41-1 of the stator core 41 to the outer peripheral portion 10-1 of the unsaturated polyester resin When the thickness from the inner circumferential portion 41-2 of the stator core 41 to the inner circumferential portion 10-2 of the unsaturated polyester resin is T2, the molded stator 10 satisfies the relationship of T1> T2 It is desirable to configure as follows.

  If the thickness T2 is too large, the diameter of the rotor 20 must be reduced, the magnetic gap between the stator core 41 and the rotor 20 becomes large, and the motor characteristics deteriorate. Therefore, in the molded stator 10 according to the present embodiment, the rigidity of the thickness T1 on the radially outer side is increased by making the thickness T1 larger than the thickness T2. The “radial direction” indicates the radial direction of the rotor 20.

  If the shaft center of the rotor 20 and the shaft center of the stator 40 are offset and an imbalance occurs in the gap between the stator core 41 and the rotor 20, the excitation force due to the eccentricity is superimposed, The eccentricity should be assembled as small as possible. It is also effective to make the thickness T2 zero because the above-mentioned gap is more likely to be unbalanced when the thickness T2 is increased, in which case between adjacent teeth 402 of the stator core 41. Fill the space with unsaturated polyester resin up to the tip of the teeth. As the excitation force, there is also a force that shakes the tip of the teeth to the left and right, and completely filling the space between the teeth leads to suppressing the influence of this force.

  Further, in the case of the stator core 41 shown in FIG. 5 and FIG. 6, by providing the unsaturated polyester resin on the divided surface 404 between the adjacent divided core portions 400, the influence of the vibration acting on the teeth 402 can be suppressed.

  Therefore, in the stator core 41, holes 405 are formed in the divided surface 404 of the annular stator core 41 shown in FIG. The holes 405 are formed by providing a groove or a notch between the adjacent back yokes 401. When the unsaturated stator is molded on the annular stator core 41, the holes 405 are filled with the unsaturated polyester resin. The hole 405 does not have to be filled with unsaturated polyester in the entire area from one end face to the other end face of the stator core 41 in the axial direction, and is slightly filled from one end face of the stator core 41 in the axial direction. Even in this case, the effect of damping the vibration can be expected. Since the larger the holes 405 are, the more magnetically affected the larger the amount of filling, the amount of filling is appropriately determined. The same effect can be obtained even when the hole 405 of the dividing surface 404 has a groove shape opened to the outer peripheral surface of the stator core 41 or a groove shape opened to the slot 406 side.

  Next, the configuration of the rotor will be described. Hereinafter, the configuration of the rotor in which all the magnetic poles are permanent magnets will be described with reference to FIGS. 7 and 8, and a general consistent pole type rotor will be described with reference to FIGS. 9 and 10.

  FIG. 7 is a cross-sectional view of a rotor in which all the magnetic poles are composed of permanent magnets. FIG. 8 is a partially enlarged view of the rotor shown in FIG. The rotor 20A shown in FIG. 7 is disposed in each of an annular rotor core 5A, ten magnet insertion holes 2A formed in the circumferential direction of the rotor core 5A, and ten magnet insertion holes 2A. And 10 permanent magnets 1A. "Circumferential direction" indicates the circumferential direction of the rotor 20A.

  The rotor core 5A is composed of a core material which is a soft magnetic material, and is configured by laminating a plurality of electromagnetic steel plates. The permanent magnet 1A is a flat plate-like rare earth magnet having a rectangular cross section, and is a neodymium sintered magnet mainly composed of Nd (neodymium)-Fe (iron)-B (boron).

  The magnet insertion hole 2A is formed of a rectangular first area 3A into which the permanent magnet 1A is inserted, and two second areas 3B into which the permanent magnet 1A is not inserted. In the longitudinal direction of the region 3A, one region is formed. The second region 3B has a function of a flux barrier that suppresses leakage flux with respect to the permanent magnet 1A inserted in the first region 3A, and the magnetic flux density distribution of the outer peripheral surface 51 of the rotor core 5A is It has a function close to a sine wave and short-circuiting the magnetic flux of the permanent magnet 1A inserted in the adjacent magnet insertion hole 2A via the rotor core 5A.

  Ten magnet insertion holes 2A are arranged at equal intervals in the circumferential direction of the rotor core 5A, and are arranged at equal distances from the rotation shaft 6. Adjacent magnet insertion holes 2A are separated from each other. The rotation axis 6 coincides with the axis of the rotor core 5A. The magnet insertion hole 2A is formed closer to the outer peripheral surface 51 of the rotor core 5A, and penetrates in the axial direction of the rotor core 5A.

  The rotor core 5A has a bridge 4A1 and a bridge 4A2. The bridge 4A1 is formed between the radially outer side of the second region 3B of the magnet insertion hole 2A and the outer peripheral surface 51 of the rotor core 5A, and the bridge 4A2 is adjacent to the second region 3B of the magnet insertion hole 2A It is formed between the magnet insertion hole 2A and the second region 3B. The rotor core 5A has a shaft insertion hole 7 at its center.

  As shown in FIG. 8, in the rotor core 5A, the thickness t1 in the radial direction of the bridge 4A2 is the same as the thickness t2 in the circumferential direction of the bridge 4A1, or slightly thicker than the thickness t2 in the circumferential direction of the bridge 4A1.

  In the rotor core 5A, the magnetic poles of the N pole and the S pole are arranged radially outward of the adjacent permanent magnets 1A, that is, on the outer peripheral surface 51 side. Therefore, the leakage flux a flows from one N pole to the other S pole. At this time, in the rotor 20A, since the bridges 4A1 and 4A2 become magnetic resistances, the amount of leakage flux is suppressed.

  FIG. 9 is a cross-sectional view of a general consistent pole type rotor. FIG. 10 is a partially enlarged view of the rotor shown in FIG. The rotor 20B shown in FIG. 9 has an annular rotor core 5B and five magnet insertion holes 2B arranged in the circumferential direction. The number of magnet insertion holes 2B is half the number of poles of the rotor 20B. The five magnet insertion holes 2B are arranged at equal intervals in the circumferential direction. The five magnet insertion holes 2B are arranged equidistant from the rotation shaft 6. The rotation axis 6 coincides with the axis of the rotor core 5B. The five magnet insertion holes 2B penetrate in the axial direction of the rotor core 5B. The magnet insertion hole 2B is formed closer to the outer peripheral surface 51 of the rotor core 5B and extends in the circumferential direction. Adjacent magnet insertion holes 2B are spaced apart. The rotor core 5B has a shaft insertion hole 7 at its center.

  The rotor core 5B is formed of a core material which is a soft magnetic material, and specifically, is formed by laminating a plurality of electromagnetic steel plates. The thickness of the magnetic steel sheet is generally 0.1 mm to 0.7 mm.

  Five permanent magnets 1B are inserted into the five magnet insertion holes 2B, respectively. The permanent magnet 1B is, for example, a flat plate having a rectangular cross section. The plate thickness of the permanent magnet 1B is, for example, 2 mm. The permanent magnet 1B is a rare earth magnet and is a neodymium sintered magnet having Nd (neodymium)-Fe (iron)-B (boron) as a main component.

  The magnet insertion hole 2B is composed of a rectangular first area 3A into which the permanent magnet 1B is inserted, and two second areas 3B into which the permanent magnet 1B is not inserted. The second area 3B is a first area In the longitudinal direction of the region 3A, one region is formed. The second region 3B has a function of a flux barrier that suppresses the leakage flux a with respect to the permanent magnet 1B inserted in the first region 3A, and the magnetic flux density distribution on the outer peripheral surface 51 of the rotor core 5B. Of the permanent magnets 1B inserted in the adjacent magnet insertion holes 2B to short-circuit the magnetic flux of the permanent magnets 1B through the rotor core 5B.

  The rotor 20B has ten magnetic poles arranged on the outer circumferential surface 51 of the rotor core 5B so as to alternate in circumferential direction. In detail, the rotor 20B is formed of five first magnetic poles each formed by five permanent magnets 1B and having the same polarity, and a rotor core 5B between the permanent magnets 1B adjacent to each other. It has five second magnetic poles having different polarities than the first magnetic pole. In the illustrated example, the first magnetic pole is N pole, and the second magnetic pole is S pole, but may be reversed. The ten magnetic poles of the rotor 20B are arranged at equal angular intervals in the circumferential direction, with the pole pitch being 360 degrees / 10 = 36 degrees.

  Thus, in the consistent pole type rotor 20B, five permanent magnets 1B having half the number of poles each provide five first magnetic poles. Furthermore, each of the five second magnetic poles having half the number of poles is formed in the core material of the rotor core 5B between the permanent magnets 1B adjacent to each other. The second magnetic pole is a so-called salient pole, and is formed by magnetizing the rotor 20B.

  Therefore, in the rotor 20B, the first magnetic pole portion 60 including the permanent magnet 1B and having the first magnetic pole and the core magnetic pole portion not including the permanent magnet 1B and having the second magnetic pole The second magnetic pole portions 61 are alternately arranged in the circumferential direction of the rotor 20B. In the case of the consistent pole type rotor 20B, the number of poles is an even number of 4 or more.

  The outer shape of the rotor core 5B is a so-called flower circle. The flower round shape is a shape in which the outer diameter of the rotor core 5B is maximum at the pole centers 62 and 63 and minimum at the interpoles 64, and the shape from the pole centers 62 and 63 to the interpoles 64 is arc-shaped It is. The pole center 62 is the pole center of the first magnetic pole, and the pole center 63 is the pole center of the second magnetic pole. In the illustrated example, the flower round shape is a shape in which ten isomorphic and same size petals are arranged at uniform angles. Accordingly, the outer diameter of the rotor core 5B at the pole center 62 is equal to the outer diameter of the rotor core 5B at the pole center 63. The circumferential width of the magnet insertion hole 2B is wider than the pole pitch.

  The rotor core 5B also has a bridge 5B1 and a bridge 5B2. The bridge 5B1 is formed between the radially outer side of the second region 3B of the magnet insertion hole 2B and the outer peripheral surface 51 of the rotor core 5B, and the bridge 5B2 is a second region 3B of the magnet insertion hole 2B, It is formed between the second regions 3B of the adjacent magnet insertion holes 2B.

  In such a consistent pole type rotor 20B, the outer magnetic poles of the adjacent permanent magnets 1B are the N pole and the N pole, and the circumferential width of the bridge 5B2 between the adjacent permanent magnets 1B Is wider than the circumferential width of the bridge 4A2 formed on the rotor 20A shown in FIG. Therefore, the distance between the adjacent bridges 5B1 is increased via the bridges 5B2, and the path of the leakage flux a leaked from one bridge 5B1 does not reach the other bridge 5B1 adjacent to the other bridge 5B1, so the leakage flux a is limited to only one bridge 5B1. It leaks to the S pole of permanent magnet 1B.

  That is, in the rotor core 5B, since the magnetic resistance due to the bridge 5B1 is smaller than that in the normal IPM, the magnetic flux generated at the N pole of one permanent magnet 1B of the adjacent permanent magnets 1B is the magnetic flux of the one permanent magnet 1B. The leakage to the S pole and the formation of the short loop of the magnetic flux increases the leakage magnetic flux.

  Further, the thickness of the bridge 5B1 has a limit in thinning for convenience of processing at the time of manufacturing the core piece constituting the rotor core 5B, so the smaller the size of the motor, the size of the rotor and the permanent magnet The ratio of the size of the bridge 5B1 to the size of is increased, and the influence of the leakage flux a is further increased. As the leakage magnetic flux a increases, the current for producing the torque of the motor increases, which leads to a decrease in motor efficiency.

  In order to solve such a problem, the rotor according to the present embodiment is configured as follows. FIG. 11 is a first cross-sectional view of a consistent pole type rotor according to the first embodiment. FIG. 12 is a second cross-sectional view of the consistent pole type rotor according to the first embodiment. FIG. 13 is a perspective view of a rotor core configured by alternately stacking the first core shown in FIG. 11 and the second core shown in FIG. 12 in the axial direction. FIG. 14 is a side view of the rotor core shown in FIG. FIG. 15 alternates between a first core block in which a plurality of first cores shown in FIG. 11 are stacked in the axial direction and a second core block in which a plurality of second cores shown in FIG. FIG. 16 is a perspective view of a rotor core configured by axially stacking on the FIG. 16 is a side view of the rotor core shown in FIG. 17 shows an axis of the first core block shown in FIG. 11 in which a plurality of first cores are stacked in the axial direction, and the second core block shown in FIG. 12 in which the plurality of second cores are stacked in the axial direction. It is a perspective view of a rotor core constituted by laminating in a direction. FIG. 18 is a side view of the rotor core shown in FIG.

  The rotor core 5 of the rotor 20 according to the present embodiment has a first core 5-1 and a second core 5-2 stacked in the axial direction of the rotor core 5. A cross-sectional view of the first core 5-1 is shown in FIG. 11, and a cross-sectional view of the second core 5-2 is shown in FIG. The differences from the rotor 20B shown in FIG. 9 will be described below, and the same components as those of the rotor 20B will be assigned the same reference numerals and detailed explanations thereof will be omitted.

  The first core 5-1 has five first insertion holes arranged in the circumferential direction, the magnet insertion holes 1C, the radially outer side of the magnet insertion holes 1C, and the outer peripheral surface of the first core 5-1. And 51 and a crimp 8 formed in the core portion. The magnet insertion hole 1C of the first core 5-1 is formed of a rectangular first area 3CA into which the permanent magnet 1B is inserted and two second areas 3CB into which the permanent magnet 1B is not inserted. The second regions 3CB are formed at one end in the longitudinal direction of the first region 3CA. The second region 3CB has a function of a flux barrier that suppresses the leakage flux with respect to the permanent magnet 1B inserted in the first region 3CA, and the magnetic flux of the outer peripheral surface 51 of the first core 5-1. The density distribution is made close to a sine wave, and the magnetic flux of the permanent magnet 1B inserted in the adjacent magnet insertion hole 1C is shorted through the first core 5-1.

  Of the two second regions 3CB of the magnet insertion hole 1C of the first core 5-1, one second region 3CB1 is opened to the outer peripheral surface 51 of the rotor core 5, and the other first core 3 The second region 3CB2 of 5-1 is not open to the outer peripheral surface 51 of the rotor core 5, and is closed in the circumferential direction. Since the second region 3CB1 has a larger magnetic resistance than the closed second region 3CB2 by being opened to the outer peripheral surface 51 of the rotor core 5, the rotation in which both of the second regions are closed is a rotation. Leakage flux can be reduced compared to the child core.

  Similar to the first core 5-1, the second core 5-2 has five second insertion holes arranged in the circumferential direction, the magnet insertion holes 1D, and the radial outside of the magnet insertion holes 1D. And a crimp 8 formed on the core portion between the outer peripheral surface 51 of the second core 5-2. The magnet insertion hole 1D of the second core 5-2 includes a rectangular first area 3DA into which the permanent magnet 1B is inserted, and two second areas 3DB into which the permanent magnet 1B is not inserted. The two regions 3DB are formed in one place at both ends in the longitudinal direction of the first region 3DA. The second region 3DB has a function of a flux barrier that suppresses the leakage flux with respect to the permanent magnet 1B inserted in the first region 3DA, and the magnetic flux of the outer peripheral surface 51 of the second core 5-2 The density distribution is made close to a sine wave, and the magnetic flux of the permanent magnet 1B inserted in the adjacent magnet insertion hole 1D is shorted through the second core 5-2.

  Of the two second regions 3DB of the magnet insertion hole 1D of the second core 5-2, one second region 3DB1 is open to the outer peripheral surface 51 of the rotor core 5, and the other second region The 3DB 2 does not open to the outer peripheral surface 51 of the rotor core 5 and is closed in the circumferential direction. Since the second region 3DB1 has a larger magnetic resistance than the closed second region 3DB2 by opening on the outer peripheral surface 51 of the rotor core 5, the rotation in which both of the second regions are closed is a rotation. Leakage flux can be reduced compared to the child core.

  The rotor core 5 shown in FIG. 13 and FIG. 14 is configured by alternately stacking the first core 5-1 and the second core 5-2 in the axial direction. The rotor core 5 shown in FIGS. 15 and 16 has a first core block 5-11 in which a plurality of first cores 5-1 shown in FIG. 11 are laminated in the axial direction, and a second core shown in FIG. A plurality of second core blocks 5-21 in which a plurality of sheets 5-2 are stacked in the axial direction is alternately stacked in the axial direction. The rotor core 5 shown in FIGS. 17 and 18 is configured by axially stacking a first core block 5-11 and a second core block 5-21.

  In the rotor core 5 according to the present embodiment, among the two bridges 5B1 present on both sides of the permanent magnet 1B shown in FIG. 10 and FIG. 11, the bridge 5B1 on one side is omitted. The magnetoresistance is larger than that of the rotor core 5 shown in FIG.

  Here, when both sides of the permanent magnet 1B are opened, the radial outer side of the permanent magnet 1B can not be supported, and the permanent magnet 1B can not be held. Therefore, a fixed part including an adhesive is required. Even when one of the magnet insertion holes is opened by using the fixing component, the bridge left on the other side of the magnet insertion hole functions as a holding portion of the permanent magnet 1B.

  However, since the moment of centrifugal force increases as the rotational speed of the rotor 20 increases, the strength with respect to the moment is insufficient with only one bridge. The rotor core 5 according to the present embodiment has a first core 5-1 in which one of the magnet insertion holes is opened and a second core in which the other of the magnet insertion holes is opened in order to eliminate the insufficient strength. 5-2 are alternately stacked. That is, a range in which the opening of the magnet insertion hole is formed on the outer periphery of the first core 5-1 is taken as a first outer periphery position, and on the outer periphery of the second core 5-2 overlapping the first core 5-1. When the range overlapping with the first outer circumferential position is taken as the second outer circumferential position, no opening is formed at the second outer circumferential position. Therefore, since the position which an opening range does not overlap by the 1st core 5-1 and the 2nd core 5-2 exists, strength shortage can be eliminated.

  Further, in the rotor core 5 according to the present embodiment, the plurality of core portions 9 are integrated by providing the caulking 8 for mutually fastening the plurality of cores stacked in the axial direction, and the centrifugal force due to rotation is permanent It can be held on the outside of the magnet 1B.

  The number of laminations of each of the first core 5-1 and the second core 5-2 may be one or more, and the strength required of the rotor core 5 and the productivity of the rotor core 5 can be used. Determined as appropriate.

  When the strength is insufficient even when the caulking 8 is provided, the rotor core 5 according to the present embodiment is configured such that the first core 5-1 and the second core 5-2 extend in the axial direction of the rotor core 5. It is configured by laminating one or more third cores having no opening. Although this configuration increases the strength, the leakage flux increases as the ratio of the third core increases, so the number of inserted third cores is determined in consideration of the centrifugal force resistance and the influence of the leakage flux. .

  The outer peripheral surface 51 of the rotor core 5 is a flower circle having a plurality of circular projections, and the pole center 62 of the first magnetic pole portion 60 corresponding to the first projection of the rotor core 5B and the rotor core 5B Between the pole center 63 of the second magnetic pole portion 61 corresponding to the second protrusion of the second magnetic pole portion 61 and the pole center 64 corresponding to the recess are provided. The round shape of the rotor core 5 makes it difficult to assemble the motor. In the case of the flower round shape, the jig structure for accurately inserting the rotor into the stator is complicated. Also, when checking the gap between the stator and the rotor with a gap gauge, the air gap changes depending on how the slot open of the stator core and the bulge and recess of the flower circle shape are opposed, It must be checked while changing the position of the rotor. Accordingly, in production, it is preferable that the outer diameter of the rotor be close to a true circle.

  Therefore, in rotor core 5 according to the present embodiment, among outer peripheral surface 51 of rotor core 5, the pole interval 64 corresponding to the recess of the flower circle is covered with resin, and the second region 3B of the magnet insertion hole is covered with resin. Further, the opening formed in the second region 3B of the magnet insertion hole is covered with a resin.

  FIG. 19 is a view showing a state in which resin is applied to the rotor core shown in FIG. 13, FIG. 15 or FIG. FIG. 20 is a partial enlarged view of a rotor core shown in FIG. As shown in FIGS. 19 and 20, the rotor core 5 is covered with resin 72 between the pole 64 between the first magnetic pole portion 60 and the second magnetic pole portion 61 in the outer peripheral surface 71 of the rotor core 5. The second region 3CB2 and the second region 3CB1 of the insertion hole are covered with the resin 72. Further, the opening 73 formed in the second region 3CB1 is covered with the resin 72. Although not shown, the second area 3DB2 shown in FIG. 12 is covered with the resin 72, and the second area 3DB1 is covered with the resin 72.

  This facilitates the assembly of the motor and also improves the strength against centrifugal force due to the rotation of the rotor. It is also possible to prevent the permanent magnet from moving due to the stator current in the magnet insertion hole. When the permanent magnet moves in the magnet insertion hole, a sound is generated that the permanent magnet collides with the wall of the magnet insertion hole, and by changing the position of the permanent magnet, the magnetic balance changes and the rotor vibration and noise are generated. , You can prevent it.

  Here, in the case where each portion is covered with resin 72 as shown in FIGS. 19 and 20, first magnetic pole portion 60 and the second magnetic pole portion 60 which are the portions of the outer peripheral surface 71 of rotor core 5 having the largest outer diameter. The thickness of the resin 72 covering the outer peripheral surface 71 of the magnetic pole portion 61 may be reduced, and burrs may be generated. Moreover, the resin 72 may be peeled off from the rotor core 5 by this. A configuration example for solving such a problem will be described below.

  FIG. 21 is a view showing the rotor core shown in FIG. 13, FIG. 15 or FIG. FIG. 22 is a partial enlarged view of a rotor core shown in FIG. FIG. 23 is a view showing a state in which the opening, the first notch and the second notch of the rotor core shown in FIG. 22 are covered with resin. FIG. 24 is a partial enlarged view of a rotor core shown in FIG.

  In FIGS. 21 and 22, the bridge 5B1 is formed on the right side of the magnet insertion hole 2B, and the opening 73 is formed on the left side of the magnet insertion hole 2B. Rotor core 5 has a first notch 74 and a second notch 75 in inter-pole portion 64 between first magnetic pole portion 60 and second magnetic pole portion 61 in outer peripheral surface 71 thereof. Is formed.

  Specifically, rotor core 5 has bridge 5B1 between pole center 62 of first magnetic pole portion 60 and pole center 63 of second magnetic pole portion 61 at one end of magnet insertion hole 2B in the circumferential direction. The first notch portion 74 is formed on one end side of the bridge 5B1 in the circumferential direction, and the second notch portion 75 is formed on the other end side of the bridge 5B1 in the circumferential direction.

  Rotor core 5 is a second projection corresponding to pole center 62 of first magnetic pole portion 60 corresponding to a first projection and a second projection of rotor core 5B at the other end of magnet insertion hole 2B in the circumferential direction. An opening 73 communicating with the recess is provided at a pole gap 64 corresponding to a recess between the pole portion 61 and the pole center 63, and a first notch 74 is formed at one end side of the opening 73 in the circumferential direction. A second notch 75 is formed at the other end of the opening 73. The radially outer surfaces of the first notch 74 and the second notch 75 have a convex shape radially inward from the virtual outer circumferential surface 71-1 of the rotor core 5.

  At one end of the magnet insertion hole 2B in the circumferential direction, the first notch 74 is a first end 74a1 formed between the pole center 62, which is the first protrusion, and the pole gap 64, which is the recess. , And has a second end 74a2 formed between the interpolar gap 64 and the bridge 5B1. At the other end of the magnet insertion hole 2B in the circumferential direction, the first notch 74 is a first end formed between the pole center 62, which is the first protrusion, and the interpole 64, which is the recess. 74b1 and has a second end 74b2 formed between the indented electrode gap 64 and the opening 73 of the magnet insertion hole 2B.

  The mold resin is injected into the first notch 74, the second notch 75, and the opening 73, whereby the first notch 74 of the rotor core 5 is formed as shown in FIGS. The second notch 75 and the opening 73 are covered with the resin 72. Thus, the radial width of the resin 72 covering the opening 73 can be made relatively thick. Therefore, generation | occurrence | production of the burr | flash mentioned above can be suppressed and peeling of resin 72 from the rotor core 5 can be suppressed further. As a result, the quality of the rotor core 5 is improved.

  Furthermore, since the centrifugal force resistance can be assisted by covering with the resin 72, the centrifugal force resistance can be further improved. Further, by covering the permanent magnet with the resin 72, oxygen and moisture do not contact the permanent magnet, and it is possible to prevent the aged deterioration of the magnetic force due to the corrosion of the permanent magnet.

  FIG. 25 is a view for explaining a step formed on the outer peripheral surface of the rotor core shown in FIG. As shown in FIG. 25, in the rotor core 5, the radius RB of the resin outer peripheral surface 71-3 of the closed resin 72-1 closing the opening 73 is formed in a portion where the outer diameter of the rotor core 5 is the largest. It is larger than the radius RA of the resin outer peripheral surface 71-2 of the resin 72. Therefore, there is a step 76 between the resin outer peripheral surface 71-3 and the resin outer peripheral surface 71-2.

  The step 76 is formed on the side of the first notch 74 and the side of the second notch 75, respectively. The step 76 on the first notch 74 side is in the circumferential direction rather than the position where the end surface 74-1 in the circumferential direction of the first notch 74 and the closing resin 72-1 formed in the opening 73 are in contact with each other. Located on the side of the center 73 a of the opening 73. The step 76 on the side of the second notch 75 is in the circumferential direction than the position where the end surface 75-1 in the circumferential direction of the second notch 75 and the closing resin 72-1 formed in the opening 73 are in contact with each other. Located on the side of the center 73 a of the opening 73.

  FIG. 26 is a view showing a state where a corner between the resin outer peripheral surface of the closed resin and the circumferential end surface of the closed resin shown in FIG. 25 is formed in an R shape or a chamfered shape. As shown in FIG. 26, the corner portion 71-5 between the resin outer peripheral surface 71-3 of the closing resin 72-1 and the circumferential end surface 71-4 of the closing resin 72-1 is formed in an R shape or a chamfered shape. As a result, it is not necessary to provide an edge portion in the mold for restraining the outer peripheral surface of the rotor core 5 in the radial direction, the wear strength of the mold is improved, and the quality of the rotor is improved. The edge portion of the mold will be described later.

  FIG. 27 is a view showing an example in which the resin outer peripheral surface of the closing resin is formed so as to eliminate the step shown in FIG. When corner portions 71-5 shown in FIG. 26 are rounded or chamfered, the resin sealing surface 72-1 is formed on the resin outer peripheral surface 71-3 so that the step 76 shown in FIG. 25 is eliminated. 2 and a continuous arc surface 71-31.

  FIG. 28 is a view showing a mold for restraining the outer peripheral surface of the rotor core in the radial direction according to the present embodiment. In FIG. 28, before the corner portion 71-5 between the resin outer peripheral surface 71-3 of the closing resin 72-1 and the circumferential end surface 71-4 of the closing resin 72-1 is formed into an R shape or a chamfered shape. The state and the state after the corner portion 71-5 has been rounded or chamfered are shown. By forming the corner portion 71-5 in an R shape or a chamfered shape, instead of providing the edge portion 81 in the mold 80, the mold 80 can be provided with a contact surface 81a having an R shape or a chamfered shape. This improves the wear strength of the mold 80 and improves the quality of the rotor. In the rotor core 5, the shapes of the first notch portion 74 and the second notch portion 75 are appropriately determined so that the thickness of the resin 72 can be maintained at a predetermined value or more, for example, 0.5 mm or more. The shape of the corner 71-5 of the surface 71-2 is appropriately determined.

  FIG. 29 is a perspective view of the rotor after resin is applied to the rotor core shown in FIG. 13, FIG. 15 or FIG. FIG. 30 is a side view of the rotor shown in FIG. According to the rotor 20 according to the present embodiment, when the outer peripheral surface of the rotor core 5 is squeezed from the radial direction by the mold when the resin 72 is filled, the resin leakage to the outer peripheral surface of the rotor core 5 is suppressed. It is also possible to improve the quality by using a slide mold using an angular structure. Further, when the resin 72 is injected, the resin injection pressure to the resin injection portion can be increased by positioning the gate for resin injection on the inner diameter side of the bridge 5B1, and the product can be manufactured stably.

  The distance from the axial center A of the rotor core 5 constituting the rotor 20 to the resin outer peripheral surface 71-2 where the outer diameter becomes large is X, and the closed resin 72 from the axial center A of the rotor core 5 X and Y have a relation of X ≧ Y, where Y is the distance to 1 to the resin outer peripheral surface 71-3. Thereby, the magnetic force generated by the rotor 20 can be utilized to the maximum.

Second Embodiment
FIG. 31 is a diagram showing an example of the configuration of the air conditioner according to Embodiment 2. The air conditioner 300 includes an indoor unit 310 and an outdoor unit 320 connected to the indoor unit 310. An indoor unit blower (not shown) is mounted on the indoor unit 310, and an outdoor unit blower 330 is mounted on the outdoor unit 320. In addition, the outdoor unit 320 is equipped with a compressor (not shown). The electric motor 100 according to the first embodiment is used for the blower and the compressor.

  Thus, cost reduction, vibration reduction and noise reduction of the air conditioner 300 can be achieved by using the motor 100 according to the first embodiment as a drive source of the air conditioner 300 blower and compressor. it can.

  The motor 100 according to the first embodiment can also be mounted on an electric device other than an air conditioner, and in this case also, the same effect as that of the present embodiment can be obtained.

  The configuration shown in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and one of the configurations is possible within the scope of the present invention. Parts can be omitted or changed.

  1A, 1B Permanent Magnet, 2A, 2B, 1C, 1D Magnet Insertion Hole, 3A, 3CA, 3DA First Region, 3B, 3B1, 3B2, 3CB, 3CB1, 3CB2, 3DB, 3DB1, 3DB2 Second Region, 4A1 , 4A2, 5B1, 5B2 bridge, 5, 5A, 5B rotor core, 5-1 first core, 5-11 first core block, 5-2 second core, 5-21 second core block , 6 rotation shaft, 7 shaft insertion hole, 8 caulking, 9 core portion, 10 molded stator, 10-1 and 41-1 outer peripheral portion, 10-2, 10a and 41-2 inner peripheral portion, 10b, 73 opening portion , 11 30a Bearing support portion, 20, 20A, 20B rotor, 21a load side rolling bearing, 21b anti load side rolling bearing, 23 shaft, 24 resin portion, 26, 26-1, 26-2 Edge sleeve, 27 shaft assembly, 30 bracket, 30b press-fit part, 40 stator, 41 stator core, 42 coil, 43 insulation part, 44b neutral point terminal, 45 board, 46 lead wire extraction part, 47 lead wire, 49b Hall IC, 50 mold resin, 60 first magnetic pole portion, 61 second magnetic pole portion, 62, 63 pole centers, 64 poles, 51, 71, 71-1 outer peripheral surface, 71-2, 71-3 resin outer periphery Face, 71-31 arc face, 71-4 circumferential end face, 71-5 corner portion, 72 resin, 72-1 closed resin, 73a center, 74 first notch, 74-1 end face, 74a1, 74b1 1 end, 74a2, 74b2 second end, 75 second notch, 75-1 end face, 76 step, 80 mold, 81 edge, 100 motor, 300 air Conditioner, 310 indoor unit, 320 outdoor unit, 330 blower for outdoor unit, 400 split core portion, 401 back yoke, 402 teeth, 403 thin wall portion, 404 split surface, 405 holes, 406 slots.

Claims (8)

With a permanent magnet,
A first core having a first protrusion and a second protrusion on the outer peripheral surface;
The first core is
A recess formed between the first protrusion and the second protrusion on the outer peripheral surface;
An insertion hole into which the permanent magnet is inserted and which has an opening communicating with the recess;
A first end formed between the first projection and the recess;
A consistent pole rotor, comprising: a second end formed between the recess and the opening. The first core is
A plurality of first magnetic poles each formed by a plurality of said permanent magnets;
A plurality of second magnetic poles each formed between adjacent permanent magnets of the first core and having a polarity different from the polarity of the first magnetic pole;
A bridge formed between the pole center of the first pole and the pole center of the second pole;
A notch formed at one end of the bridge in the circumferential direction;
A notch formed at the other end of the bridge in the circumferential direction;
The opening formed between the pole center of the first magnetic pole and the pole center of the second magnetic pole and opening on the outer peripheral surface of the first core;
A notch formed at one end of the opening in the circumferential direction;
A notch formed at the other end of the opening;
A contorted pole rotor according to claim 1 comprising   The rotor according to claim 2, further comprising a resin covering the notches and the opening. The first core is
There is a step between the outer peripheral surface of the resin covering the outer peripheral surface of the first magnetic pole and the outer peripheral surface of the resin covering the opening,
The step is formed in a notch formed at one end and the other end of the opening in the circumferential direction,
The position of the step in the circumferential direction is located at the center of the opening in the circumferential direction rather than the position where the end face of the notch in the circumferential direction and the resin covering the opening are in contact with each other. Described pole type rotor.   5. The rotation according to claim 4, wherein a corner between the outer peripheral surface of the resin covering the opening and the end face of the resin covering the opening in the circumferential direction has an R shape or a chamfered shape. Child.   The consistent pole type rotor according to any one of claims 2 to 5, wherein a gate for resin injection is located on the inner diameter side of the bridge.   A motor comprising the stator of the contingent pole type according to any one of claims 1 to 6 and a stator.   An air conditioner comprising the motor according to claim 7.

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