JP6565228B2 - Electric motor - Google Patents

Description

  The present invention relates to a surface magnet type electric motor including an annular stator having a field coil and a rotor having a permanent magnet exposed from the outer surface of a rotor yoke.

  2. Description of the Related Art Conventionally, a surface permanent magnet (SPM) electric motor that can secure a large effective magnetic flux amount (linkage magnetic flux amount between a stator and a rotor) with a small volume is known (for example, Patent Documents 1 and 2). reference).

  In the electric motor of Patent Document 1, a plurality of permanent magnets are bonded to the outer surface of the rotor yoke, and the permanent magnets adjacent in the circumferential direction are fixed with a nonmagnetic adhesive. Moreover, the cylindrical protective material is arrange | positioned on the outer periphery of these permanent magnets.

  In the electric motor of Patent Document 2, a magnet holding groove that is recessed from the outer surface in the direction of the rotational axis of the rotor is formed in the rotor yoke, and a permanent magnet is inserted into the magnet holding groove. In the magnet holding groove, the upper width on the outer peripheral side is made narrower than the bottom width on the rotating shaft side, and the permanent magnet is formed in the same shape as the magnet holding groove. Further, the outer peripheral surface of the permanent magnet and the outer peripheral surface of the rotor yoke are configured to be flush with each other.

JP 2009-44797 A JP 2013-21826 A

  The surface magnet type electric motor described above is a technique for preventing the permanent magnet from falling off due to the centrifugal force accompanying the rotation of the rotor. However, in the electric motor described in Patent Document 1, since the permanent magnet is bonded to the outer surface of the rotor yoke, it is difficult to position the permanent magnet. If the circumferential interval between the permanent magnets becomes non-uniform, the circumferential magnetic flux density varies and the controllability of the electric motor is reduced. Furthermore, since permanent magnets adjacent to each other in the circumferential direction are bonded together or a protective material is installed on the outer circumference of the permanent magnet, the number of assembling steps and material costs are increased.

  In the electric motor described in Patent Document 2, since the permanent magnet is inserted into the magnet holding groove, the positioning of the permanent magnet is easy, and the assembly man-hour is not increased. However, since the outer peripheral surface of the permanent magnet and the outer peripheral surface of the rotor yoke are configured to be flush with each other, a closed magnetic flux is generated at the end surface of the permanent magnet adjacent in the circumferential direction, and the effective magnetic flux amount is reduced. As a result, the permanent magnet is increased in size to obtain a desired rotational torque. On the other hand, when a permanent magnet containing an expensive rare earth such as neodymium is used, it is desired to make the permanent magnet compact by increasing the amount of effective magnetic flux.

  As described above, there is a demand for an electric motor with high controllability while holding a permanent magnet capable of increasing the effective magnetic flux with a simple configuration.

The characteristic configuration of the electric motor according to the present invention includes an annular stator having a field coil, and a rotating shaft centered in an inner space of the stator, which is recessed from a cylindrical outer surface toward the rotating shaft core. A rotor yoke having a plurality of magnet holding grooves, an outer wall portion projecting radially outward from the outer surface in a state of being mounted in the magnet holding groove, and a back wall portion facing the rotation axis And a plurality of permanent magnets having a pair of side wall portions that are both end portions in the circumferential direction of the rotor yoke, and the side wall portion extends from the end portion of the back wall portion in the radially outward direction. A side surface and a second side surface formed so that the pair of side wall portions approach each other from the first side surface toward the end of the outer wall portion, and the circumferential direction of the magnet holding groove On both ends of the rotating shaft core from the outer surface As the distance from each other increases, the distance between each other increases, and a pair of contact portions that contact a part of the second side surface is formed. The second side surface includes a contacted portion that contacts the contact portion, and the contact in that it has a, a projection projecting radially outward from the outer table surface without contact to the section.

  If the outer wall of the permanent magnet is formed in an arc shape while the permanent magnet is accommodated in the magnet holding groove as in this configuration, positioning can be performed so that the intervals in the circumferential direction of the permanent magnets are uniform. Further, if the outer wall portion of the permanent magnet is formed in an arc shape parallel to the inner surface of the stator, the permanent magnet can be uniformly brought close to the inner peripheral surface of the stator. For this reason, the electric motor of this structure can obtain a desired rotational torque while improving the controllability by making the magnetic flux density of the permanent magnets arranged in the circumferential direction uniform.

  In this configuration, since the outer wall portion of the permanent magnet protrudes radially outward from the outer surface of the rotor, there is a portion where the rotor yoke does not exist between the side wall portions of the permanent magnets adjacent in the circumferential direction. . As a result, the inconvenience that the magnetic flux on the side wall of the permanent magnet draws a loop through the rotor yoke, as in the electric motor described in Patent Document 2, can be suppressed. Therefore, the amount of effective magnetic flux can be increased and the permanent magnet can be made compact.

  Further, in this configuration, at both ends of the magnet holding groove, there is a pair of abutting portions that increase in distance from each other toward the rotation axis from the outer surface of the rotor. It is made to contact | abut to a part of 2nd side surface formed so that a pair of side wall part may approach. That is, the permanent magnet that has received the centrifugal force accompanying the rotation of the rotor is prevented from falling off due to the contact between the contact portion that becomes wider toward the rotation axis and the second side surface. For this reason, unlike the electric motor described in Patent Document 1, it is not necessary to separately provide a pressing member for the rotating magnet, and the number of assembling steps can be reduced.

  Therefore, it was possible to provide an electric motor with high controllability while holding a permanent magnet that can increase the effective magnetic flux amount with a simple configuration.

  Another characteristic configuration is that the permanent magnet is configured such that an angle between the back wall portion and the first side surface is 90 degrees or more.

  Like this structure, the angle of a back wall part and a 1st side surface is comprised at 90 degree | times or more, and the crack at the time of shape | molding a permanent magnet, a crack, etc. are suppressed. Therefore, since the mounting posture of the permanent magnet with respect to the magnet holding groove is stabilized, the contact posture between the second side surface and the contact portion becomes appropriate, and the permanent magnet can be held with high accuracy.

  Another characteristic configuration is that the magnetic flux direction of the side wall portion of the permanent magnet is inclined with respect to the central magnetic flux direction in the circumferential direction when viewed in the direction along the rotation axis.

  If the magnetic flux direction of the side wall portion is inclined when the permanent magnet is magnetized as in this configuration, the magnetic flux that moves back and forth between the side wall portions of the adjacent permanent magnets is smoothly connected along the outer peripheral surface of the rotor yoke. As a result, the polarity of the permanent magnet does not change abruptly with the rotation of the rotor, and the smooth rotation of the electric motor can be realized by suppressing the generation of cogging torque. As a result, the controllability of the electric motor can be improved.

It is sectional drawing of an oil pump. It is II-II sectional drawing of FIG. It is sectional drawing which shows a rotor yoke and a permanent magnet. It is an expanded sectional view showing a rotor yoke and a permanent magnet. It is a perspective view of a permanent magnet. It is a schematic diagram which shows the flow of the magnetic flux in a magnetic flux concentration pattern. It is a figure which shows the relationship between the magnetic flux density according to a magnetization radius, and cogging torque. 6 is an enlarged cross-sectional view showing a rotor yoke and a permanent magnet according to another embodiment 1. FIG. It is an expanded sectional view showing a rotor yoke and a permanent magnet according to another embodiment 2. It is an expanded sectional view showing a rotor yoke and a permanent magnet according to another embodiment 3.

  Embodiments of an electric motor according to the present invention will be described below with reference to the drawings. In the present embodiment, the electric motor M will be described as an example used for the water pump P. However, the present invention is not limited to the following embodiments, and various modifications can be made without departing from the scope of the invention.

[Basic configuration]
As shown in FIG. 1, a resin motor housing 1 that houses an electric motor M and a resin pump housing 2 that houses an impeller 6 are connected, and a control case C is formed integrally with the motor housing 1 to form a water. A pump P is configured.

  One end of a support shaft 4 arranged coaxially with the rotary shaft core X is supported by the motor housing 1, and the other end is supported by the pump housing 2, and is fitted to the support shaft 4. The resin-made rotating shaft 5 is supported rotatably. The rotor 20 of the electric motor M is provided on one end side of the rotating shaft 5, and a plurality of impellers 6 are integrally formed on the other end side of the rotating shaft 5.

  The electric motor M is configured as a brushless DC motor, and the rotation of the rotor 20 is controlled by a control element mounted on the control board 7 accommodated in the control case C.

  The electric motor M of the present embodiment can be used as a drive source for an oil pump that supplies lubricating oil in a vehicle engine in addition to a water pump. For example, it can be used for assisting hydraulic pressure to the valve timing control device (VVT) when idling is stopped. Moreover, it can also be used as an opening / closing of a window of a vehicle or a driving source of a steering wheel, and may be used other than a vehicle.

  Hereinafter, an example in which the electric motor M is configured as a brushless DC motor will be described. However, since it is basically the same configuration as the three-phase AC motor, it may be configured as a three-phase AC motor and is not particularly limited.

(Electric motor)
As shown in FIG. 1 and FIG. 2, the electric motor M is supported in an annular shape around the rotation axis X and is rotatably supported around the rotation axis X in the internal space of the stator 10. The rotor 20 is provided.

  The stator 10 is configured by laminating a large number of electromagnetic steel plates, and is configured as a 9-slot type in which a field coil 13 is wound via an insulator 12 on nine teeth 11 formed integrally with the stator 10. ing. However, the number of teeth portions 11 is not limited to nine.

  The rotor 20 is configured in a generally cylindrical shape by including a rotor yoke 21 that rotates integrally with the rotary shaft 5 and a plurality of permanent magnets 30 that are supported in a manner that a part of the rotor yoke 21 is exposed on the outer periphery of the rotor yoke 21. . FIG. 2 shows a six-pole type having six permanent magnets 30. However, the number of permanent magnets 30 is not limited to six.

  As shown in FIG. 3, the rotor yoke 21 is formed by laminating a number of magnetic steel plates formed by stamping or the like, and a plurality of magnets that are recessed in the direction of the rotation axis X are held on the outer surface of the rotor yoke 21. Grooves S (six locations in the present embodiment) are formed. The permanent magnets 30 are mounted in the plurality of magnet holding grooves S, respectively.

  As shown in FIG. 4, the magnet holding groove S has a flat groove bottom surface Sa and a pair of groove side surfaces Sb that are both ends in the circumferential direction. The groove side surface Sb rises from the groove bottom surface Sa at an acute angle in the radially outward direction. That is, the pair of groove bottom surfaces Sa are inclined so as to approach from the groove bottom surface Sa to the outer surface of the rotor yoke 21. As a result, the pair of groove side surfaces Sb has a pair of contact portions Sba that are spaced apart from each other toward the rotation axis X from the outer surface of the rotor yoke 21 (bent at an acute angle toward the rotation axis X). Is formed.

  The rotor yoke 21 is formed with dowel-shaped portions between a large number of magnetic steel plates in order to perform caulking in the direction of the rotation axis X with a large number of magnetic steel plates being stacked. The relative positional relationship of the steel plates is maintained, and the respective separation is prevented. In addition, since an insulating film is formed on the surface of the magnetic steel plate, an insulating adhesive may be used as the insulating film so that the positional relationship between the plurality of magnetic steel plates may be maintained.

  As the permanent magnet 30, a strong magnet containing a rare earth such as neodymium, samarium or dysprosium is used. The permanent magnet 30 is formed into the shape shown in FIGS. 4 to 5, but the material of the magnet may be formed by cutting or using a mold. Further, as a process of assembling the rotor 20, the magnetized permanent magnet 30 may be inserted into the magnet holding groove S. After inserting the magnet material demagnetized into the magnet holding groove S, the magnet 20 is magnetized to be permanent. The magnet 30 may be used. In the following description, magnetization is performed after a magnet material is inserted into the magnet holding groove S, but the target to be inserted into the magnet holding groove S is the permanent magnet 30.

  The permanent magnet 30 is mounted in the magnet holding groove S, protrudes radially outward from the outer surface of the rotor yoke 21 and is formed in an arc shape, and a planar back wall portion facing the rotation axis X 32 and a pair of side wall portions 33 which are both end portions in the circumferential direction (width direction) of the rotor yoke 21. The connection portion between the outer wall portion 31 and the side wall portion 33 and the connection portion between the back wall portion 32 and the side wall portion 33 have a smooth shape having a predetermined curvature.

  As shown in FIG. 2, the outer surface of the outer wall portion 31 has an arc shape parallel to the arc shape of the inner peripheral surface of the stator 10. Thereby, it becomes possible to make the permanent magnet 30 approach uniformly with respect to the inner peripheral surface of the stator 10, and a large rotational torque can be obtained. As shown in FIG. 3, the distance (maximum radius R <b> 1) between the rotation axis X of the rotor yoke 21 and the outer surface of the outer wall portion 31 is configured to be larger than the radius R <b> 2 of the rotor yoke 21. That is, there is a portion where the rotor yoke 21 does not exist between the side wall portions 33 of the permanent magnets 30 adjacent in the circumferential direction. For this reason, the inconvenience that the magnetic flux passing through the side wall 33 of the permanent magnet 30 draws a loop via the rotor yoke 21 is suppressed, and the amount of effective magnetic flux that functions as rotational torque can be increased. In particular, if a magnetic flux concentration pattern, which will be described later, is used in combination with the electric motor M in the present embodiment, the magnetic fluxes between the side wall portions 33 of the adjacent permanent magnets 30 are smoothly connected as shown in FIG. The amount of effective magnetic flux that does not contribute can be eliminated.

  As shown in FIGS. 4 to 5, the side wall portion 33 of the permanent magnet 30 includes a first side surface 33 a having a planar shape (straight cross section) extending radially outward from an end portion of the back wall portion 32, and a first side surface 33 a. The second side surface 33b has a planar shape (linear cross section) formed so that the pair of side wall portions 33 approach each other from the side surface 33a toward the end of the outer wall portion 31. A part of the second side surface 33b is in contact with the contact portion Sba of the groove side surface Sb of the magnet holding groove S. Since the permanent magnet 30 of this embodiment has the planar side wall part 33, the magnet particles sintered at the time of molding are cornered like the crescent-shaped permanent magnet 30 which does not have the side wall part 33, for example. There is no inconvenience that it is difficult to flow. Therefore, the permanent magnet 30 can be easily formed.

  Further, as shown in FIG. 4, the crossing angle α1 between the first side surface 33a of the permanent magnet 30 and the groove bottom surface Sa of the magnet holding groove S is set to about 90 degrees. For this reason, cracks, chipping, and the like when molding the permanent magnet 30 are suppressed. Therefore, since the mounting posture of the permanent magnet 30 with respect to the magnet holding groove S is stabilized, the contact posture between the second side surface 33b and the contact portion Sba becomes appropriate, and the permanent magnet 30 can be held with high accuracy. This intersection angle α1 is larger than the intersection angle β (for example, 80 degrees) between the groove side surface Sb and the groove bottom surface Sa of the magnet holding groove S. That is, the first side surface 33 a of the permanent magnet 30 and the groove side surface Sb of the magnet holding groove S of the rotor yoke 21 are separated from each other.

  On the other hand, the crossing angle α2 between the second side surface 33b and the groove bottom surface Sa of the magnet holding groove S is configured to be substantially equal to the crossing angle β between the groove side surface Sb of the magnet holding groove S and the groove bottom surface Sa. 33b is in contact along the contact portion Sba. As a result, even when the permanent magnet 30 receives a centrifugal force due to the rotation of the rotor 20, the contact portion Sba, which is wider in the direction of the rotation axis X, and the second side surface 33b contact each other, so that the permanent magnet 30 falls off. do not do.

(Permanent magnet magnetization direction)
Next, the magnetization direction of the permanent magnet 30 will be described. As shown in FIG. 6, the permanent magnet 30 according to the present embodiment has a magnetic flux direction of the side wall portion 33 that is inclined with respect to the central magnetic flux direction in the circumferential direction when viewed in the direction along the rotation axis X. The magnetic flux group passing through 30 is magnetized so as to converge at the convergence point T. That is, generally, it is a magnetic flux concentration pattern with respect to a parallel pattern in which the central magnetic flux direction and the magnetic flux direction of the side wall 33 are parallel.

  As a result, the magnetic flux traveling between the side wall portions 33 of the adjacent permanent magnets 30 is smoothly connected along the outer periphery of the rotor yoke 21. As a result, the polarity of the permanent magnet 30 does not change abruptly as the rotor 20 rotates, and the smooth rotation of the electric motor M can be realized while suppressing the generation of cogging torque.

  Subsequently, the optimization of the magnetization radius L of the electric motor M (the distance between the rotational axis X and the convergence point T shown in FIG. 6) will be verified. In this embodiment, attention is paid to the magnetization radius L in the magnetic flux concentration pattern. This is based on the knowledge that as the magnetizing radius L is decreased, the magnetic flux passing through the side wall portion 33 of the permanent magnet 30 is along the circumferential direction, and the cogging torque is decreased. On the other hand, since the magnetic flux direction is dispersed as the magnetization radius L is reduced, it is considered that the amount of magnetic flux passing through the permanent magnet 30 is reduced. Therefore, the magnetization radius L that can significantly reduce the cogging torque while suppressing the decrease degree of the magnetic flux density will be verified.

  Here, as shown in FIG. 4, for example, the maximum radius R1 = 22.5 mm, which is the distance between the rotational axis X of the rotor yoke 21 and the outer surface of the outer wall portion 31, the radius R2 = 22 mm of the rotor yoke 21, and a permanent magnet. The maximum radial height (maximum thickness K) of 30 was set to about 3.5 mm. Further, the intersection angle α1 of the first side surface 33a of the permanent magnet 30 and the groove bottom surface Sa of the magnet holding groove S is about 90 degrees, and the intersection angle α2 of the second side surface 33b and the groove bottom surface Sa of the magnet holding groove S is 80 degrees. The crossing angle β between the groove side surface Sb of the magnet holding groove S and the groove bottom surface Sa was set to about 80 degrees.

  FIG. 7 shows the relationship between the integrated value of the cogging torque and the integrated value of the magnetic flux density within a predetermined rotation angle range. In addition, the number described in the curve in the figure indicates the magnetization radius L.

  As shown in FIG. 7, there are two change points (magnetization radius L = about 23 mm, about 36 mm) where the cogging torque becomes a minimum value. In particular, between the magnetizing radius L = 100 mm (approximate to the parallel pattern) and the magnetizing radius L = 36 mm, the cogging torque is greatly reduced even though the magnetic flux density is not so much reduced. I understand that. Specifically, when the magnetizing radius L is about 36 mm, the cogging torque is reduced by about 54% compared to the magnetizing radius L = 100 mm, while the decrease in the magnetic flux density is limited to about 4%. I was able to. The magnetization radius L that can reduce the cogging torque by about 30% is approximately 60 mm. On the other hand, when the magnetizing radius L is about 23 mm, the magnetic flux density is reduced by about 16% compared to the magnetizing radius L = about 100 mm, but the cogging torque can be almost eliminated.

  By the way, the magnetization radius L cannot be smaller than the maximum radius R1 = 22.5 mm. That is, the optimum lower limit value of the magnetizing radius L is preferably set in the vicinity of the maximum radius R1 of the rotor 20 (L / R1 = 1.0). On the other hand, the optimum upper limit value of the magnetizing radius L is set in the vicinity of the magnetizing radius L = 60 mm (L / R1 = 2.7) which can significantly reduce the cogging torque even if the magnetic flux density is slightly reduced. Is preferred. The surface magnet type electric motor M requiring a large rotational torque is more preferably a magnetization radius L = 30 to 60 mm (L / R1 = 1.3 to 2.7). Further, as the electric motor M that requires a large rotational torque and quiet performance, the magnetization radius L is preferably 30 to 50 mm (L / R1 = 1.3 to 2.2).

[Another embodiment 1]
In the embodiment described above, the intersecting angle α1 between the first side surface 33a of the permanent magnet 30 and the groove bottom surface Sa of the magnet holding groove S is set to a right angle. However, as shown in FIG. Larger). Thereby, the crack, chipping, etc. at the time of shaping the permanent magnet 30 can be further suppressed.

[Another embodiment 2]
Moreover, as shown in FIG. 9, you may set the 1st side surface 33a to R shape. In this case, since the distance to the first side surface 33a of the adjacent permanent magnet 30 is shortened, the magnetic flux that has passed through the first side surface 33a can be smoothly transferred to the first side surface 33a of the adjacent permanent magnet 30.

[Another embodiment 3]
In the embodiment described above, the back wall portion 32 of the permanent magnet 30 is formed flat, but the back wall portion 32 may be formed in an R shape as shown in FIG. Thereby, since the radial height of the permanent magnet 30 is shortened, the volume of the expensive permanent magnet 30 is further reduced, and the material cost can be saved.

[Other Embodiments]
(1) When the electric motor M is used for the water pump P as described above, it is preferable to cover the outer periphery of the rotor 20 composed of the rotor yoke 21 and the permanent magnet 30 with a resin from the viewpoint of rust prevention. On the other hand, when the electric motor M is used as a drive source for the oil pump, even if the permanent magnet 30 receives a centrifugal force due to the rotation of the rotor 20, the contact portion Sba of the rotor yoke 21 that becomes wider in the direction of the rotation axis X. And the second side surface 33b of the permanent magnet 30 come into contact with each other and the permanent magnet 30 does not fall off, so the outer periphery of the rotor 20 does not have to be covered with resin.
(2) In the above-described embodiment, the second side surface 33b of the permanent magnet 30 is formed in a flat shape and is brought into contact with the contact portion Sba of the magnet holding groove S. However, the permanent magnet 30 does not fall off. Thus, the second side surface 33b may be provided with a curve or uneven. Moreover, you may provide a crease | fold point in the middle part of the planar 1st side surface 33a of the permanent magnet 30, or the 2nd side surface 33b. As a result, the contact area between the second side surface 33b and the contact portion Sba is reduced, so that the closing magnetic flux can be further reduced.

  The present invention is applicable to a surface magnet type electric motor in which a permanent magnet is exposed from the outer surface of a rotor yoke.

DESCRIPTION OF SYMBOLS 10 Stator 13 Field coil 21 Rotor yoke 30 Permanent magnet 31 Outer wall part 32 Back wall part 33 Side wall part 33a First side surface 33b Second side surface S Magnet holding groove Sb Groove side surface (both ends)
Sba contact part X rotation axis

Claims (3)

An annular stator having field coils;
A rotor yoke having a plurality of magnet holding grooves that rotate around an axis of rotation in the internal space of the stator and that are recessed from a cylindrical outer surface in the direction of the axis of rotation;
An outer wall portion that protrudes radially outward from the outer surface in a state of being mounted in the magnet holding groove, is formed in an arc shape, a back wall portion that faces the rotating shaft core, and both end portions in the circumferential direction of the rotor yoke. A plurality of permanent magnets having a pair of side wall portions,
The side wall portion includes a first side surface extending in the radially outward direction from an end portion of the back wall portion, and the pair of side wall portions as they go from the first side surface to the end portion of the outer wall portion. And a second side formed to approach,
At both ends in the circumferential direction of the magnet holding groove, a distance from each other increases toward the rotating shaft core from the outer surface, and a pair of contact portions that contact a part of the second side surface are formed,
The second aspect is an electric motor having a projection projecting said abutting portion abuts on the abutted portion from the outer table surface radially outside without abutting on the abutting portion.   The electric motor according to claim 1, wherein the permanent magnet has an angle of 90 degrees or more between the back wall portion and the first side surface.   The electric motor according to claim 1 or 2, wherein the permanent magnet has a magnetic flux direction of the side wall portion inclined with respect to a magnetic flux direction at a center in the circumferential direction when viewed in a direction along the rotation axis.

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