JP7104306B2 - Motors and compressors - Google Patents

Description

The present disclosure relates to motors and compressors.

In a motor, the outer diameter of the rotor may be formed so as to decrease from one end to the other end. For example, in some conventional motors, the outer diameter of the rotor that is cantilevered is reduced from one end to the other so that the rotor and the stator do not come into contact with each other even if the rotor swings during operation. (See, for example, Patent Document 1).

Japanese Patent No. 5972014

However, in the example of the patent document, since the outer circumference of the rotor is cut in order to change the outer diameter of the rotor from one end to the other end, the manufacturing cost tends to increase.

An object of the present disclosure is to suppress the manufacturing cost when the motor adopts a structure in which the outer diameter of the rotor is changed from one end to the other end.

The first aspect of the present disclosure is
Rotation axis (2a) and
A rotor (20) for driving the rotating shaft (2a) is provided.
The rotor (20) is a core block in which a block member (31) made of a magnetic material and a bond magnet (36) provided over one layer or multiple layers in the radial direction to form a magnetic pole are integrally formed. (30) is formed by stacking one or more in the axial direction.
The bond magnet (36) has a gate mark (37) on one end side in the axial direction.
On the end face of the core block (30), a line (Lr) connecting the end point in the clockwise direction and the axial center (O) of the rotation axis (2a) when the bond magnet (36) is viewed from the axial direction, The line that divides the angle formed by the line (Ll) connecting the end point in the counterclockwise direction and the axis (O) into two equal parts is defined as the center line (CL) of the bond magnet (36).
The intersection of the center line (CL) and the innermost circumference of the bond magnet (36) is defined as the center point (CP) of the bond magnet (36).
The distance from the axis (O) to the center point (CP) is defined as the radius (R1, R2) of the core block (30).
The thickness of the bond magnet (36) is defined to be obtained in the radial direction at the center point (CP), and the parameters t1, t2, R1 and R2 are defined, respectively.
t1, t2: When the bond magnet (36) of each magnetic pole has one layer, the thickness of the bond magnet (36) is the total. ,
R1, R2: core block radius,
However, t1 and R1 are values obtained at the end of the core block (30) on the gate mark (37) side, and t2 and R2 are on the opposite side of the core block (30) from the gate mark (37). If you define it as the value obtained at the end of
The parameters have a relationship of R1> R2, t1> t2, R1-R2 = t1-t2.
In the core block (30), the distance (r1) from the axis (O) to the center point (CP) on the end face on the gate mark (37) side and the end face on the side opposite to the gate mark. , The motor is characterized in that the distance (r2) from the axis (O) to the center point (CP) is equal.

In the first aspect, when the block member (31) and the bond magnet (36) are integrally molded, the block member (31) is deformed. Therefore, in this aspect, it is possible to suppress the cost when the motor (2) adopts a structure in which the outer diameter of the rotor (20) is changed from one end to the other end.

A second aspect of the present disclosure is, in the first aspect, the first aspect.
The block member (31) is a motor characterized in that it is formed by laminating electromagnetic steel sheets.

In the second aspect, since the block member (31) is formed by laminating electromagnetic steel sheets, the block member (31) is easily deformed in the process of integral molding.

A third aspect of the present disclosure is the first or second aspect.
Only one end of the rotating shaft (2a) is supported by the bearing (3a).
In the core block (30) located at the position farthest from the bearing (3a), the end surface on the side closer to the bearing (3a) is the lower surface, and the end surface on the side opposite to the lower surface is the upper surface.
A point (a) on the outermost circumference of the upper surface, which is included in the axial cross section of the core block (30) passing through the center line (CL).
When there is only one core block (30), the angle formed by the tangent line (L2) drawn from the point (a) to the outer peripheral surface of the core block (30) with the upper surface is θ1.
When there are two or more core blocks (30), the tangent line drawn from the point (a) to each core block (30) through the point (a) is the farthest from the bearing (3a). Let θ1 be the one that maximizes the angle between the core block (30) and the upper surface.
Assuming that the maximum tilt angle of the rotation axis (2a) is Max (θ0),
The motor is characterized in that the value of the parameter is set so that Max (θ0) ≦ (θ1-90 °).

In the third aspect, even if the inclination of the rotor (20) is maximized, the contact between the rotor (20) and the stator (10) is prevented.

A fourth aspect of the present disclosure is a compressor driven by a motor according to any one of the first to third aspects.

FIG. 1 shows a compressor according to the first embodiment. FIG. 2 schematically shows the cross-sectional shape of the motor. FIG. 3 is a perspective view of the rotor. FIG. 4 shows a plan view of the rotor as viewed from the axial direction. FIG. 5 is a cross-sectional view of the rotor corresponding to the VV cross section of FIG. FIG. 6 is a plan view of the plate member. FIG. 7 shows a vertical cross section of a molding die for injection molding. FIG. 8 is a fixed plan view. FIG. 9 shows a movable cross section. FIG. 10 schematically shows the state of the bonded magnet material in the magnet slot at the initial stage of the injection process. FIG. 11 schematically shows the cross-sectional shape of the completed core block. FIG. 12 is a diagram illustrating a definition such as a radius. FIG. 13 schematically shows the positional relationship between the rotor in the tilted state and the stator. FIG. 14 schematically shows the configuration of the rotor according to the second embodiment. FIG. 15 shows an example in which θ1 is defined by a tangent line in the core block on the side close to the bearing. FIG. 16 illustrates how to stack core blocks. FIG. 17 illustrates how to stack core blocks. FIG. 18 illustrates how to stack core blocks. FIG. 19 illustrates how to stack core blocks. FIG. 20 illustrates how to stack core blocks. FIG. 21 shows a bond magnet according to a modification of the magnet shape 1. FIG. 22 shows the bond magnet of the second modification of the magnet shape. FIG. 23 shows a bond magnet of a modified example 3 of the magnet shape. FIG. 24 shows a bond magnet of a modified example 4 of the magnet shape. FIG. 25 shows another arrangement example of the bond magnet. FIG. 26 illustrates a rotor having a continuous skew structure. FIG. 27 illustrates a rotor having a step skew structure.

<< Embodiment 1 >>
FIG. 1 shows a compressor (1) according to the first embodiment. The compressor (1) is used, for example, in a refrigerant circuit (not shown) of an air conditioner. The compressor (1) includes a compression mechanism (3) that compresses a fluid (refrigerant in a refrigerant circuit in this example), a motor (2) that drives the compressor, and a casing (4) that houses them. .. As can be seen from FIG. 1, in the compressor (1), the rotating shaft (2a) of the motor (2) is installed so as to be vertical. Further, in the present embodiment, the motor (2) is arranged above the compression mechanism (3).

Various compression mechanisms can be adopted as the compression mechanism (3). For example, a rotary compression mechanism or a scroll compression mechanism can be adopted as the compression mechanism (3). In this example, the compression mechanism (3) sucks the fluid (refrigerant) from the suction pipe (3b) provided on the side surface of the casing (4), and discharges the compressed fluid into the casing (4). The fluid discharged into the casing (4) is discharged from a discharge pipe (3c) provided on the upper part (upper end end plate) of the casing (4).

[Structure of motor (2)]
FIG. 2 schematically shows the cross-sectional shape of the motor (2). The motor (2) is a magnet-embedded motor. As shown in FIG. 2, the motor (2) includes a stator (10), a rotor (20), and a rotating shaft (2a).

In the following description, the axial direction means the direction of the axial center of the rotation axis (2a), and the radial direction means the direction orthogonal to the axial direction. The outer peripheral side means a side far from the axis, and the inner peripheral side means a side close to the axis.

<Stator (10)>
The stator (10) includes a cylindrical stator core (11) and a coil (16).

The stator core (11) is a so-called laminated core. The stator core (11) is formed by laminating a plurality of plate-shaped members formed by punching an electromagnetic steel sheet into the same shape by a press working machine in the axial direction. The stator core (11) includes one back yoke portion (12), a plurality of (six in this example) teeth portions (13), and a plurality of brim portions (14).

The back yoke portion (12) is an annular portion in a plan view on the outer peripheral side of the stator core (11). The stator core (11) is fixed by being fitted so that a part of the outer peripheral surface of the back yoke portion (12) is in contact with the inner peripheral surface of the casing (4).

Further, each tooth portion (13) is a rectangular cuboid portion extending in the radial direction in the stator core (11). A coil (16) is wound around each tooth portion (13) by, for example, a centralized winding method, and a coil slot (15) for accommodating the coil (16) in a space between the tooth portions (13) adjacent to each other. ). As described above, an electromagnet is configured in each tooth portion (13).

The brim portion (14) is a portion that continuously projects to both sides on the inner peripheral side of each tooth portion (13). Therefore, the brim portion (14) is formed to have a larger width (length in the circumferential direction) than the teeth portion (13). The inner peripheral surface of the brim portion (14) is a cylindrical surface, and the cylindrical surface faces the outer peripheral surface (cylindrical surface) of the rotor (20) at a predetermined distance (air gap (G)). ..

<Rotor (20)>
FIG. 3 shows a perspective view of the rotor (20), and FIG. 4 shows a plan view of the rotor (20) as viewed from the axial direction. Further, FIG. 5 shows a vertical cross-sectional view of the rotor (20). FIG. 5 corresponds to the VV cross section of FIG. The rotor (20) comprises a core block (30). The core block (30) referred to here is one in which a block member (31), which is a laminated core, and a bond magnet (36) forming a magnetic pole are integrally molded.

In this embodiment, the number of core blocks (30) is one. Therefore, in this embodiment, the core block (30) and the rotor (20) may be equated. Also, in this example, the core block (30) includes four bonded magnets (36). That is, the rotor (20) has four magnetic poles.

In general, end plates (for example, disk-shaped members formed of a non-magnetic material such as stainless steel) and balance weights are provided at both ends in the axial direction of the rotor. The end plate and balance weight are not shown.

-Block member (31)-
The block member (31) is formed by vertically laminating a plurality of plate members (32) formed by punching an electromagnetic steel sheet having a thickness of, for example, 0.3 to 0.5 mm into the same shape by a press working machine. Has been done. FIG. 6 shows a plan view of the plate member (32) in the present embodiment.

The plate member (32) is formed with a through hole (35) for forming a slot (34) for a magnet, which will be described later. In this example, a cylindrical block member (31) is formed by stacking a large number of plate members (32) and joining the plate members (32) with each other by caulking. The electromagnetic steel sheet, which is the raw material of the plate member (32), is preferably insulated and coated from the viewpoint of suppressing the generation of eddy currents.

In the block member (31), four magnet slots (34) for accommodating the bond magnet (36) are arranged around the axis (O) of the block member (31) at a pitch of 90 °. These magnet slots (34) penetrate the block member (31) in the axial direction. In the magnet slot (34), the shape of the cross section orthogonal to the rotation axis (2a) is the rectangular main body portion orthogonal to the radius of the block member (31) and the outer peripheral side from both ends of the main body portion, respectively. It is a shape that combines a bent and extended rectangular part.

As can be seen from FIG. 4, the plate member (32) has a portion (hereinafter referred to as a bridge portion (32b)) having a thin radial width in the vicinity of both ends of the magnet slot (34). In the block member (31), the block (hereinafter referred to as the outer peripheral block (31a)) facing the outer peripheral side surface of the magnet slot (34) and the magnet slot (34) are separated by these bridge portions (32b). It can be seen that the blocks facing the inner peripheral surface are connected to each other (see FIG. 4).

Further, the block member (31) has a shaft hole (33) formed at the center thereof. In the shaft hole (33), a rotating shaft (2a) for driving a load (compression mechanism (3) in this example) is fixed by tightening fitting (for example, shrink fitting). Therefore, the axis (O) of the block member (31) and the axis of the rotation axis (2a) are coaxial.

Further, only one end side of the rotating shaft (2a) is supported by the bearing (3a) provided in the compression mechanism (3), and the other end of the rotating shaft (2a) is not supported. That is, in the motor (2), the rotating shaft (2a) is cantilevered and supported. Therefore, in the motor (2), the rotor (20) may be slightly tilted during operation due to, for example, the clearance between the rotating shaft (2a) and the bearing (3a).

-Bond magnet (36)-
The bond magnet (36) is formed by mixing fine powdery or granular ferrite magnets or rare earth magnets, which are magnet materials, with a binder such as nylon resin or polyphenylene sulfide resin (PPS resin) and solidifying them. It is a permanent magnet.

In the present embodiment, as will be described later, when the core block (30) is manufactured, the magnet slot (34) of the block member (31) is provided with a non-magnetic powdery or granular magnet material and a binder. A mixed bond magnet material (36a) is supplied and magnetized to form a bond magnet (36).

Both end faces of the bond magnet (36) are exposed to an opening (hereinafter, slot opening (34a)) in the magnet slot (34). A gate mark (37) is formed on one of the exposed end faces. Here, the gate mark (37) is a material supply mark having a gate shape (usually circular) formed corresponding to the position of the gate (48) provided in the molding die (40) described later.

The gate mark (37) formed on the end face of the bond magnet (36) may be removed by post-processing. In general, even if the gate mark (37) is removed by post-processing, the trace of the presence of the gate mark (37) can be visually recognized.

[Manufacturing method of rotor (20)]
To manufacture the rotor (20), it is necessary to manufacture the core block (30). Hereinafter, the manufacturing method of the core block (30) will be mainly described.

<Molding mold used for manufacturing>
In the manufacturing process of the core block (30), the block member (31) and the bond magnet (36) are integrally molded by injection molding. FIG. 7 shows a vertical cross section of a molding die (40) for injection molding used in manufacturing the core block (30). As shown in FIG. 7, the molding die (40) is composed of a fixed die (41) and a movable die (42). Note that FIG. 7 shows a state in which the block member (31) is placed in the mold.

As shown in FIG. 7, the fixed mold (41) is formed with a recess (41a) into which the block member (31) can be arranged in an internally fitted shape. The movable mold (42) is a plate-shaped mold provided on the opening side of the recess (41a). Then, the fixed mold (41) and the movable mold (42) are molded, and the recess (41a) of the fixed mold (41) is closed by the movable mold (42), whereby the cavity (43) is formed inside. It is configured to be.

FIG. 8 is a plan view of the fixed type (41). FIG. 8 also shows a state in which the block member (31) is placed in the mold. As shown in FIG. 8, in the fixed mold (41), permanent magnets (44) and pole pieces (45) are alternately arranged in the circumferential direction around the recess (41a). The number of pole pieces (45) is provided according to the number of magnetic poles so as to correspond one-to-one with the bond magnet (36) of the rotor (20).

Therefore, the fixed mold (41) is provided with four pole pieces (45) and also provided with the same number of permanent magnets (44) as the pole pieces (45). With this configuration, in the molding die (40), a magnetic field can be generated in the cavity (43). Specifically, in the molding die (40), each pole piece (45) applies magnetic flux from the contacting permanent magnet (44) to the block member (31) set in the cavity (43).

FIG. 9 shows a cross section of the movable type (42). FIG. 9 corresponds to the IX-IX cross section of FIG. In FIG. 9, the position of the block member (31) set in the recess (41a) is shown by a chain double-dashed line. The movable type (42) is formed with a spool (46), a runner (47) branched from the spool (46), and a gate (48) continuously opened in the cavity (43).

The number of gates (48) is the same as that of magnet slots (34). Each gate (48) is provided with an opening facing the slot opening (34a) of the magnet slot (34). Hereinafter, the opening of the gate (48) is referred to as a gate opening (48a).

<injection molding>
To form the bond magnet (36), first, the molding die (40) is mounted on the injection molding machine, and the block member (31) is placed in the recess (41a) of the fixed die (41). At this time, the block member (31) is positioned in the rotational direction so that the slot opening (34a) and the gate opening (48a) correspond to each other (see FIG. 9).

Next, the fixed mold (41) and the movable mold (42) are molded. At this time, the block member (31) is arranged in the cavity (43) of the molding die (40).

Subsequently, the bond magnet material (36a) is injected and supplied from the injection molding machine to the molding die (40), and the bond magnet material is injected from the slot opening (34a) of the block member (31) set in the cavity (43). (36a) is injected (hereinafter, this step is referred to as an injection step), and the magnetic field of the permanent magnet (44) is used to orient the bonded magnet material (36a) in the magnet slot (34).

Here, the material for a bonded magnet (36a) used in the present embodiment is a mixture of a non-magnetic powdery or granular magnet material and a binder. The bond magnet material (36a), which has been heated and kneaded in an injection molding machine to form a fluid, flows through the spool (46) and runner (47) of the movable type (42) from the gate (48) to the cavity (43). ), And flows into the magnet slot (34). In FIG. 7, the material for the bond magnet (36a) passing through the spool (46), the runner (47), and the gate (48) is shown by hatching.

Further, FIG. 10 schematically shows the state of the bonded magnet material (36a) in the magnet slot (34) at the initial stage of the injection process. In the injection step, the pressure (hereinafter referred to as flow pressure) generated by the bonded magnet material (36a) in the cavity (43) is the largest directly under the gate opening (48a). Therefore, the material for the bond magnet (36a) is orthogonal to the injection direction due to the magnetic flux from the pole piece (45) while the area directly below the gate opening (48a) rises downward in the magnet slot (34). The magnetic field orientation and magnetization are performed while spreading in the direction (here, the horizontal direction).

The bonded magnet material (36a) thus spread in the horizontal direction is pushed by the bonded magnet material (36a) continuously injected from the gate (48) to the back of the magnet slot (34) (FIG. Pushed into (below 10), the bond magnet material (36a) eventually reaches the bottom surface of the recess (41a).

The injection amount of the injection molding machine is specified so that the bond magnet material (36a) is filled in each magnet slot (34). When a specified amount of injection is completed by the injection molding machine, a bond magnet (36) is formed in the magnet slot (34). In this bond magnet (36), a gate mark (37) corresponding to the position of the gate (48) is formed on the end face on the injection side of the material (36a) for the bond magnet. The other end surface of the bond magnet (36) is formed on a flat surface on which the bottom surface of the recess (41a) of the fixed type (41) is transferred.

In the injection step, the flow pressure acts on the inner surface of the magnet slot (34) (for example, the surface facing the outer peripheral block (31a)). When the flow pressure acting on the inner surface of the magnet slot (34) becomes greater than or equal to a predetermined value, the bridge portion (32b) having the lowest strength in the block member (31) is deformed.

With the deformation of the bridge portion (32b), the outer peripheral block (31a) moves toward the outer peripheral side. The deformation of the bridge portion (32b) may be elastic deformation or plastic deformation. Even if the deformation of the bridge portion (32b) is elastic deformation, the deformed state is maintained if the bonded magnet material (36a) solidifies.

In the block member (31), the amount of deformation differs for each plate member (32). This is because the acting flow pressure differs depending on the position where the plate members (32) are laminated. Therefore, the radius of the completed core block (30) (the exact definition of the radius will be described later) is from the end face on the side facing the gate opening (48a) (hereinafter referred to as the gate side end face) to the bottom surface of the recess (41a). It gradually changes toward the end face on the side facing the surface (hereinafter referred to as the end face on the anti-gate side).

FIG. 11 schematically shows the cross-sectional shape of the completed core block (30). In FIG. 11, R1 is the radius of the core block (30) obtained at the end face on the gate side, and R2 is the radius of the core block (30) obtained at the end face on the opposite gate side.

FIG. 12 is a diagram illustrating a radius definition in the core block (30). Lr in FIG. 12 refers to the axis of the end point (Pr) and the rotation axis (2a) in the clockwise direction of the bond magnet (36) when the bond magnet (36) formed in the core block (30) is viewed from the axial direction. It is a line connecting the heart (O). Further, Ll refers to the end point (Pl) and the axial center (O) of the bond magnet (36) formed in the core block (30) in the counterclockwise direction when viewed from the axial direction. It is a connecting line.

Further, CL is a line (hereinafter referred to as a center line (CL)) that divides the angle formed by the line (Ll) and the line (Lr) into two equal parts at the end face of the core block (30). Here, the innermost point (CP) is defined as the point included in the intersection (line segment) with the bond magnet (36) on the center line (CL). Then, the distance from the axis (O) to the outermost circumference of the core block (30) through the center point (CP) is defined as the radius of the core block (30).

Further, in FIG. 11, t1 is the thickness of the bond magnet (36) obtained at the end face on the gate side, and t2 is the thickness of the bond magnet (36) obtained at the end face opposite to the end face on the gate side. .. However, the thickness of the bond magnet (36) is defined as what is obtained in the radial direction at the center point (CP).

When the parameters t1, t2, R1 and R2 are defined in this way, in the core block (30), the following dimensional relationship is established due to the deformation of the block member (31) due to injection molding.

R1> R2
t1> t2
R1-R2 = t1-t2
The above dimensional relationship is established in the core block (30) because the outer peripheral block (31a) moves due to the flow pressure.

In the core block (30), the distance (r1) from the axial center (O) to the center point (CP) on the gate side end face and the axial center (O) to the center point (CP) on the opposite gate side end face. Is equal to the distance to (r2). That is, r1 = r2. The reason why r1 = r2 is that in each plate member (32), the portion on the inner peripheral side of the bond magnet (36) is hardly deformed by injection molding.

In order to prevent the rotor (20) and the stator (10) from coming into contact with each other when the rotor (20) swings during operation, it is necessary to appropriately control the amount of deformation of the block member (31) in the manufacturing process. There is. FIG. 13 schematically shows the positional relationship between the rotor (20) in the tilted state and the stator (10). FIG. 13 is a vertical cross section (hereinafter referred to as a representative vertical cross section) passing through the center line (CL). Parameters such as the angle are defined as follows in order to determine the conditions under which the rotor (20) and the stator (10) do not come into contact with each other during operation.

First, the end face of the rotor (20) on the side closer to the bearing (3a) is defined as the lower surface. The end face on the opposite side to the lower surface is defined as the upper surface. In FIG. 13, L is the distance from the rotation center of the rotation axis (2a) to the upper surface. The center of rotation corresponds to the point (c) in FIGS. 11 and 13.

Further, the point (a) is a point on the outermost circumference of the upper surface and is included in the representative vertical cross section (see FIG. 13). Further, the straight line connecting the center of rotation (c) and the point (a) is defined as L1. The angle (θr) is the angle formed by the center line (L0) and the straight line (L1) of the rotation axis (2a) in a non-tilted state.

From the above definition, the angle (θr) can be expressed by the following equation.

Further, in the representative vertical cross section, the tangent line drawn from the point (a) to the outer peripheral surface (contour line when viewed in cross section) of the core block (30) is defined as L2. The angle between this tangent (L2) and the upper surface is defined as θ1. Further, let d be the distance between the point (a) and the inner peripheral surface of the stator (10) when the rotor (20) is not tilted.

Here, the inclination of the rotor (20) is set to θ0. For example, assuming that the point (a) of the rotor (20) comes into contact with the inner peripheral surface of the stator (10), θ0 satisfies the following equation (see FIG. 13).

Therefore, in order to prevent the point (a) of the rotor (20) from contacting the inner peripheral surface of the stator (10), if the maximum value of θ0 (hereinafter referred to as the maximum tilt angle) satisfies the following equation. good. In the following, the maximum tilt angle will be described as Max (θ0).

Max (θ0) ≤ (θ1-90 °)
When designing the motor (2), the parameters (for example, R1 and R2) may be determined so as to satisfy this equation. In order to obtain a core block (30) having a predetermined parameter by injection molding, molding conditions such as a filling pressure at the time of injection molding and a temperature of a block member (31) at the time of injection molding (more specifically, a preheating temperature) are required. You just have to adjust.

The rotating shaft (2a) is fixed to the core block (30) manufactured as described above by, for example, shrink fitting (an example of tightening fitting). The rotation shaft (2a) may be shrink-fitted to the block member (31) before the bond magnet (36) is formed by injection molding.

[Effect in this embodiment]
As described above, in the present embodiment, in the step of forming the bond magnet (36), the radius of the block member (31) is deformed from one end to the other by using the flow pressure. That is, it is not necessary to provide a process (for example, a cutting process) for processing a shape in which the outer diameter changes from one end to the other end as in the conventional case.

Therefore, according to the present embodiment, it is possible to suppress the cost when adopting a structure in which the outer diameter of the rotor is changed from one end to the other end.

Further, in the present embodiment, since the block member (31) is configured by laminating electromagnetic steel sheets, the block member (31) can be easily deformed in the injection molding process.

Further, since the values of each parameter (R1, R2, etc.) are set so that Max (θ0) ≦ (θ1-90 °), the contact between the rotor (20) and the stator (10) is ensured. Can be prevented.

<< Embodiment 2 >>
FIG. 14 schematically shows the configuration of the rotor (20) according to the second embodiment. In this example as well, the motor (2) is installed so that its rotating shaft (2a) is vertical. Also, the bearing (3a) is only present under the motor (2).

As shown in FIG. 14, the rotor (20) of this embodiment includes two core blocks (30). All of these core blocks (30) are vertically stacked so that the end face on the small diameter side (end face on the radius (R2) side) is on the upper side. That is, in this example, the end face on the small diameter side of the lower core block (30) and the end face on the large diameter side (end face on the radius (R1) side) of the upper core block (30) are in contact with each other. These core blocks (30) have the same configuration as the core block (30) of the first embodiment, and are manufactured by the same construction method as that of the first embodiment.

In order to prevent the rotor (20) and the stator (10) from coming into contact with each other when the rotor (20) swings during the operation of the motor (2), the same concept as in the first embodiment is applied to the rotor (20). Applicable to design and manufacturing. However, in the case of a rotor (20) having a plurality of core blocks (30), the definitions of the point (a) and the tangent line (L2) are modified as follows.

That is, in a rotor (20) having a plurality of core blocks (30), the point (a) is a point above the upper surface (referred to as the farthest upper surface) of the core block (30) farthest from the bearing (3a). Moreover, it is a point included in the representative vertical cross section. Further, the tangent line (L2) has the maximum angle formed with the farthest upper surface among the tangent lines drawn from the point (a) to each core block (30) in the representative vertical cross section.

In the example of FIG. 14, in the representative vertical cross section, the tangent line drawn on the outer peripheral surface of the core block (30) on the side far from the point (a) to the bearing (3a) is L2. The angle between the tangent line (L2) and the farthest upper surface is θ1. For reference, FIG. 15 shows an example in which θ1 is defined by a tangent line in the core block (30) on the side close to the bearing (3a).

Under this definition, if Max (θ0) ≤ (θ1-90 °), the rotor (20) can be prevented from contacting the stator (10). Even if the core block (30) is provided in three or more stages, contact between the rotor (20) and the stator (10) is prevented if this relationship is established.

[Effect in this embodiment]
As described above, also in the present embodiment, the block member (31) is deformed by utilizing the flow pressure in the step of forming the bond magnet (36). Therefore, also in this embodiment, it is possible to suppress the cost when adopting a structure in which the outer diameter of the rotor is changed from one end to the other end.

Further, since the block member (31) of the present embodiment has the same configuration as that of the first embodiment, the block member (31) can be easily deformed in the injection molding process.

Further, since each parameter (R1, R2, etc.) is set so that Max (θ0) ≦ (θ1-90 °), contact between the rotor (20) and the stator (10) is surely prevented. be able to.

<< Modification of Embodiment 2 >>
The method of stacking the two core blocks (30) constituting the rotor (20) is an example, and may be as shown in FIG. 16, for example. In the example of FIG. 16, both are arranged so that the end faces on the large diameter side of the core block (30) overlap each other to form the rotor (20).

The number of core blocks (30) is also an example. That is, the rotor (20) is formed by stacking one or more core blocks (30) in the axial direction. FIGS. 17 to 20 show an example in which the rotor (20) is configured by three core blocks (30).

<< Other Embodiments >>
The embodiment may have the following configuration.

(1) Deformation Example of Shape of Bond Magnet (36) The shape of the bond magnet (36) is not limited to the shape shown in the above embodiment. For example, a bond magnet (36) having the following shape may be adopted.

-Modification example of magnet shape 1-
FIG. 21 shows a bond magnet (36) according to a modification of the magnet shape 1. In this modification, the bond magnet (36) has a rectangular cross-sectional shape. FIG. 21 shows a line (Ll), a line (Lr), and a center line (CL) in this magnet shape (hereinafter, the same applies).

-Modification example of magnet shape 2-
FIG. 22 shows the bond magnet (36) of the second modification of the magnet shape. In this modification, the bond magnet (36) has a cross-sectional shape in which the outer peripheral side is a protruding arc.

-Modification example of magnet shape 3-
FIG. 23 shows a bond magnet (36) of a modified example 3 of the magnet shape. In this modification, the bond magnet (36) has a cross-sectional shape in which the inner peripheral side is a protruding arc (hereinafter referred to as an inverted arc).

-Modification example of magnet shape 4-
FIG. 24 shows a bond magnet (36) of a modified example 4 of the magnet shape. In this example, the magnetic slots of each magnetic pole are partitioned by a bridge-shaped member (named the center bridge (34b)). That is, in this modification, two bond magnets (36) are provided on each magnetic pole. Each bond magnet (36) has an inverted arc cross-sectional shape.

In this modification as well, the parameters (t1, t2, R1, R2) are determined corresponding to the respective bond magnets (36), not in magnetic pole units. Similarly, in this example, the line (Ll), line (Lr), and center line (CL) are defined for each bond magnet (36).

(2) Deformation Example of Arrangement of Bond Magnet (36) The arrangement of the bond magnet (36) is not limited to the arrangement of the embodiment. FIG. 25 shows another arrangement example of the bond magnet (36). In this example, at each magnetic pole, a bond magnet (36) having a cross-sectional shape of an inverted arc is provided in multiple layers in the radial direction. The parameters t1 and t2 in this example are the total thickness of the bonded magnets (36) of each layer connected in the radial direction.

Again, the thickness of each bonded magnet (36) is determined in the radial direction at the center point (CP). In this modification, the bond magnets (36) are provided in multiple layers in the radial direction, and the center point (CP) in this case is related to the center line (CL) for each bond magnet (36). Defined accordingly. That is, in the center line (CL), the point included in the intersection (line segment) with the bond magnet (36) of interest, the innermost circumference is referred to as the center point (CP) of the bond magnet (36) of interest. Define.

Further, t1 is a value obtained on the gate side end face, and t2 is a value obtained on the anti-gate side end face. Also in this example, R1> R2, t1> t2, R1-R2 = t1-t2, r1 = r2 are established.

(3) Adoption of skew structure A so-called skew structure may be adopted for the rotor (20). The skew structure is useful for reducing cogging torque. The skew structure can be considered as a so-called continuous skew structure and a step skew structure. The continuous skew structure is a structure in which the bond magnet (36) is continuously twisted from one end to the other end in the axial direction in the rotor (20). In this example, it can be realized by gradually shifting the phase of each plate member (32) in the rotational direction from one end to the other end in the axial direction of the block member (31). FIG. 26 illustrates a rotor (20) having a continuous skew structure.

On the other hand, the step skew structure is configured so that the position of the bond magnet (36) is gradually displaced in the rotational direction from one end to the other end in the axial direction of the rotor (20). To realize this, for example, two core blocks (30) are prepared, and the two core blocks (30) are overlapped so as to be out of phase with each other in the rotation direction. FIG. 27 illustrates a rotor (20) having a step skew structure.

(4) Number of magnetic poles, etc. The number of magnetic poles formed in the rotor (20) and the number of tooth portions (13) provided in the stator (10) are also examples, and are not limited to those described as the respective embodiments and modifications. ..

(5) Arrangement of motor (2), etc. The arrangement of motor (2) in the compressor (1) is also an example. The motor (2) can also be used in a compressor having a structure in which the compression mechanism (3) is provided above the motor (2).

Although the embodiments and modifications have been described above, it will be understood that various modifications of the forms and details are possible without departing from the purpose and scope of the claims. Further, the above embodiments and modifications may be appropriately combined or replaced as long as the functions of the subject of the present disclosure are not impaired.

As described above, the present disclosure is useful for motors and compressors.

1 Compressor 2 Motor 2a Rotating shaft 3a Bearing 20 Rotor 30 Core block 31 Block member 36 Bond magnet 37 Gate mark

Claims (4)

Rotation axis (2a) and
A rotor (20) for driving the rotating shaft (2a) is provided.
The rotor (20) is a core block in which a block member (31) made of a magnetic material and a bond magnet (36) provided over one layer or multiple layers in the radial direction to form a magnetic pole are integrally formed. (30) is in the axial directiontwoIt is formed by stacking the above
The bond magnet (36) has a gate mark (37) on one end side in the axial direction.
On the end face of the core block (30), a line (Lr) connecting the end point in the clockwise direction and the axis (O) of the rotation axis (2a) when the bond magnet (36) is viewed from the axial direction, The line that divides the angle formed by the line (Ll) connecting the end point in the counterclockwise direction and the axis (O) into two equal parts is defined as the center line (CL) of the bond magnet (36).
The intersection of the center line (CL) and the innermost circumference of the bond magnet (36) is defined as the center point (CP) of the bond magnet (36).
From the axis (O) to the center point (CP)The distance to the outermost circumference of the core block (30)Defined as the radius (R1, R2) of the core block (30),
The thickness of the bond magnet (36) is defined to be obtained in the radial direction at the center line (CL), and the parameters t1, t2, R1 and R2 are defined, respectively.
t1, t2: When the bond magnet (36) of each magnetic pole has one layer, the thickness of the bond magnet (36) is the total. ,
R1, R2: core block radius,
However, t1 and R1 are values obtained at the end of the core block (30) on the gate mark (37) side, and t2 and R2 are on the opposite side of the core block (30) from the gate mark (37). If you define it as the value obtained at the end of
The parameters have a relationship of R1> R2, t1> t2, R1-R2 = t1-t2.
In the core block (30), the distance (r1) from the axis (O) to the center point (CP) on the end face on the gate mark (37) side and the end face on the side opposite to the gate mark. , The distance (r2) from the axis (O) to the center point (CP) is equalnine,
Only one end of the rotating shaft (2a) is supported by the bearing (3a).
In the core block (30) located farthest from the bearing (3a), the end face on the side opposite to the gate mark (37) is on the side farther from the bearing (3a) than the end face on the gate mark (37) side. It is arranged in the direction that becomes
A motor characterized by that. In claim 1,
The block member (31) is a motor characterized in that it is formed by laminating electromagnetic steel sheets. In claim 1 or 2,
Only one end of the rotating shaft (2a) is supported by the bearing (3a).
In the core block (30) located at the position farthest from the bearing (3a), the end surface on the side closer to the bearing (3a) is the lower surface, and the end surface on the side opposite to the lower surface is the upper surface.
A point (a) on the outermost circumference of the upper surface, which is included in the axial cross section of the core block (30) passing through the center line (CL).
Of the tangents drawn from the point (a) to each core block (30) through the point (a), the angle formed by the upper surface of the core block (30) farthest from the bearing (3a) is the maximum. Let θ1 be
Assuming that the maximum tilt angle of the rotation axis (2a) is Max (θ0),
The motor is characterized in that the value of the parameter is set so that Max (θ0) ≦ (θ1-90 °). A compressor driven by the motor according to any one of claims 1 to 3.

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