JP7284334B1 - Core unit and rotor - Google Patents

Abstract

An object of the present invention is to provide an iron core unit and a rotor that can maintain the shape of a powder magnetic core and improve the cooling performance of the iron core. A core unit includes at least one core and a pipe. At least one iron core is formed with a dust core hole penetrating in the first direction. A pipe extends in a first direction. Furthermore, the pipe is inserted into the dust core hole. As a result, an iron core unit is realized in which the shape of the powder magnetic core can be maintained and the cooling performance of the iron core is improved. [Selection drawing] Fig. 2A

Description

The present disclosure relates to core units and rotors.

Conventionally, an iron core unit including a dust core is known. For example, Patent Literature 1 discloses a stator core composed of a dust core as an example of an iron core unit (see FIG. 2 of the same literature).

JP 2008-271713 A

If, for example, a tensile stress occurs in the dust core of the core unit, the dust core may be damaged, making it difficult to maintain the shape of the core unit. Also, the temperature of the core unit may rise due to, for example, iron loss.

An object of the present disclosure is to provide an iron core unit and a rotor that can maintain the shape of the dust core and improve the cooling performance of the iron core.

A core unit according to at least one embodiment of the present disclosure includes:
an iron core including at least one powder magnetic core having a powder magnetic core hole penetrating in a first direction;
a pipe extending in the first direction and inserted into the dust core hole;
Prepare.

A rotor according to an embodiment of the present disclosure includes:
a ring unit including the plurality of core units and a plurality of non-magnetic bodies arranged alternately with the plurality of core units in a circumferential direction perpendicular to the first direction;
a pair of flanges respectively connected to both ends of the ring unit in the first direction, the pair of flanges being configured to be connected to a rotating shaft extending in the first direction;
with
At least one flange hole communicating with the inner space of the pipe of each of the plurality of core units is formed in each of the flanges.

ADVANTAGE OF THE INVENTION According to this indication, the iron core unit which can maintain the shape of a powder magnetic core and improved the cooling performance of an iron core, and a rotor are provided.

1 is a schematic diagram of a core unit according to one embodiment; FIG. It is a schematic diagram showing an iron core concerning one embodiment. It is a schematic diagram showing an iron core concerning other embodiments. It is a schematic diagram showing a joint structure of an iron core and a pipe concerning one embodiment. It is a schematic diagram showing a detailed structure of a pipe according to one embodiment. It is the schematic which shows the joining structure of the iron core and pipe which concern on other embodiment. 1 is a schematic diagram showing a pipe according to one embodiment (first illustration); FIG. Fig. 2 is a schematic diagram showing a pipe according to one embodiment (second illustration); FIG. 3 is a schematic diagram showing a pipe according to one embodiment (third illustration); 1 is a schematic diagram of a rotor according to one embodiment; FIG. FIG. 4 is a schematic diagram showing part of the configuration of a ring unit according to one embodiment; 1 is a schematic diagram of a magnetic geared electric machine according to one embodiment; FIG.

Several embodiments of the present disclosure will now be described with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of the components described as the embodiment or shown in the drawings are not meant to limit the scope of the present disclosure, but are merely illustrative examples. do not have.
For example, expressions denoting relative or absolute arrangements such as "in a direction", "along a direction", "parallel", "perpendicular", "center", "concentric" or "coaxial" are strictly not only represents such an arrangement, but also represents a state of relative displacement with a tolerance or an angle or distance to the extent that the same function can be obtained.
For example, expressions such as "identical", "equal", and "homogeneous", which express that things are in the same state, not only express the state of being strictly equal, but also have tolerances or differences to the extent that the same function can be obtained. It shall also represent the existing state.
For example, expressions that express shapes such as squares and cylinders do not only represent shapes such as squares and cylinders in a geometrically strict sense, but also include irregularities and chamfers to the extent that the same effect can be obtained. The shape including the part etc. shall also be represented.
On the other hand, the expressions "comprising", "including", or "having" one component are not exclusive expressions excluding the presence of other components.
In addition, the same code|symbol may be attached|subjected about the same structure and description may be abbreviate|omitted.

<1. Overview of Core Unit 10>
FIG. 1 is a schematic exploded perspective view of a core unit 10 according to one embodiment of the present disclosure. A core unit 10 that may be incorporated into an armature includes a core 60 extending in a first direction.
When the iron core unit 10 is incorporated in a stator as an example of an armature, an armature coil may be wound around the iron core 60 . When the iron core unit 10 is incorporated in the rotor 30 (see FIG. 7) as an example of the armature, the armature coil does not have to be wound around the iron core 60 . The first direction may be any direction, and may be a vertical direction, a horizontal direction, or a direction intersecting the vertical direction and the horizontal direction.

An insertion hole 68 is formed in the center of the iron core 60 . Although the insertion hole 68 illustrated in FIG. 1 is a through hole that penetrates in the first direction, the present disclosure is not limited to this, and the insertion hole 68 is closed on one side in the first direction and only may be opened (details will be described later). The core unit 10 further includes a pipe 80 extending in the first direction, and the pipe 80 is inserted into the insertion hole 68 of the core 60 . The fit between the pipe 80 and the insertion hole 68 may be an interference fit, an intermediate fit, or a clearance fit. Adhesive 9 (see FIG. 3) may be interposed between the pipe 80 and the inner peripheral surface that defines the insertion hole 68, regardless of which fitting method is employed. A pipe 80 (see FIG. 1) inserted into the insertion hole 68 supports the iron core 60 .

In the example of FIG. 1, the insertion hole 68 has a circular shape when viewed in the first direction, and the pipe 80 has a cylindrical shape, but the present disclosure is not limited to this. In another embodiment, the insertion hole 68 may have a rectangular shape when viewed from the first direction, in which case the pipe 80 is formed in the shape of a square cylinder. In the following description, an example in which a pipe 80 is inserted into a single circular insertion hole 68 will be mainly described.

Also, although a single insertion hole 68 is formed in the example of FIG. 1, the present disclosure is not so limited. In another embodiment, two insertion holes 68 may be spaced apart in a direction perpendicular to the first direction (not shown). In this case, both of the two insertion holes 68 may be through holes penetrating in the first direction. Alternatively, two insertion holes 68 may be spaced apart in the first direction. In either embodiment, two pipes 80 may be inserted into the two insertion holes 68, respectively.

<2. Details of Structure of Iron Core 60>
2A, 2B are schematic diagrams illustrating cores 60A, 60B (60) according to some embodiments of the present disclosure. Iron cores 60A, 60B (60) include at least one dust core 70. An iron core 60A illustrated in FIG. 2A includes a plurality of powder magnetic cores 70 successively laminated in a first direction. The iron core 60B illustrated in FIG. 2B includes a steel plate laminate 79 including a plurality of steel plates 77 continuously laminated in a first direction, and a pair of pressure plates arranged on both sides of the steel plate laminate 79 in the first direction. A powder magnetic core 70 is included.

A dust core hole 75 penetrating in the first direction is formed in the central portion of each dust core 70 illustrated in FIGS. 2A and 2B. The dust core hole 75 is a component of the insertion hole 68 . In the example of FIG. 2A, an insertion hole 68A (68) formed by a plurality of powder magnetic core holes 75 is a through hole penetrating in the first direction. In the example of FIG. 2B , a steel plate hole 78 is formed in the central portion of each steel plate 77 , and the insertion hole 68 is formed by a plurality of steel plate holes 78 and two dust core holes 75 . In the example of FIG. 2B as well, the insertion hole 68 is a through hole penetrating in the first direction.

According to the above configuration, the dust core 70 is formed with the dust core hole 75 into which the pipe 80 is inserted. As a result, it is possible to suppress the temperature rise of the iron core 60 caused by, for example, the generation of eddy currents. In addition, the powder magnetic core 70 may be damaged, for example, when a tensile stress is generated in the first direction. In this respect, according to the above configuration, since the pipe 80 is inserted into the dust core hole 75 , even if the dust core 70 is damaged, the flake dust core 70 can be prevented from falling off the iron core 60 . Therefore, the iron core unit 10 in which the shape of the dust core 70 can be maintained and the cooling performance of the iron core 60 is improved is realized.

Note that the temperature rise of the iron core 60 is not limited to the generation of eddy currents. For example, in an embodiment in which an armature coil is wound around an iron core 60, heat generated by energization in the armature coil may be transferred to the iron core 60 and the temperature of the iron core 60 may rise. Also in this embodiment, the cooling performance of the iron core 60 can be expected to be improved by air flowing through the inner space of the pipe 80 inserted into the dust core hole 75 . Also, the insertion hole 68 is not limited to being a through hole penetrating in the first direction. More specifically, the steel plate hole 78 may not be formed in the steel plate 77 of FIG. 2B. In this case, two insertion holes 68 are formed by two dust cores 70 arranged on both sides of the steel plate laminate 79 . That is, the two insertion holes 68 are spaced apart in the first direction. Both of the two insertion holes 68 are closed by the steel plate laminate 79 (that is, one side of each insertion hole 68 in the first direction is closed by the steel plate laminate 79). In this embodiment, two pipes 80 are inserted into the two dust core holes 75, respectively. Even in this case, since air can flow through the inner space of the pipe 80, an improvement in the cooling performance of the iron core 60 can be expected. Also, it is possible to prevent the flake dust core 70 from falling off the iron core 60 .

Although not an essential configuration of the present disclosure, in the example of FIGS. 2A and 2B, a single pipe 80 longer in the first direction than cores 60A and 60B (60) extends from one end of core 60 to the other. It is inserted across the side edges. According to the above configuration, since the pipe 80 is inserted so as to penetrate the core 60 , the pipe 80 can support the core 60 more firmly, and the mechanical strength of the core unit 10 can be improved.

In the example of FIG. 2A, as described above, the core 60A (60) includes a plurality of powder cores 70 continuously stacked in the first direction, and a single pipe 80 is provided for each powder core hole 75. inserted into the Further, in the example of FIG. 2B, the iron core 60B (60) includes two dust cores 70 laminated in the first direction with a steel plate laminate 79 interposed therebetween, and a single pipe 80 is provided in each dust core hole. It is plugged into 75. According to the above configuration, since the iron core 60 includes a plurality of dust cores 70, each dust core 70 forming the iron core 60 can be miniaturized. As a result, the work of inserting each dust core 70 into the pipe 80 in the assembly process of the iron core 60 can be simplified. In addition, since the dust core 70 is made smaller, the molding pressure required for the molding machine that performs the molding process of the dust core 70 can be reduced, and the manufacture of the dust core 70 can be facilitated.
As described above, the steel plate hole 78 may not be formed in the steel plate 77 of FIG. may In this case, each pipe 80 is shorter than the core 60 in the first direction. Also in this embodiment, since the iron core 60 includes a plurality of dust cores 70, each dust core 70 can be miniaturized. Therefore, the above advantages are obtained.

The pipe 80 according to one embodiment of the present disclosure is preferably made of a non-magnetic material, more preferably made of a non-magnetic metallic material. Examples of non-magnetic metal materials include aluminum, austenitic stainless steel, and copper. According to the above configuration, since the pipe 80 is made of a non-magnetic material, the occurrence of hysteresis loss due to the magnetization of the pipe 80 can be suppressed, and the magnetic flux modulation function of the iron core 60 can be maintained. Further, since the pipe 80 is made of a non-magnetic metal material, the thermal conductivity of the pipe 80 is improved, and the thermal conductivity from the dust core 70 to the pipe 80 can be improved. Note that the pipe 80 may be made of a non-metallic, non-magnetic material such as a resin material. Even in this case, the above advantages of suppressing the generation of hysteresis loss due to the magnetization of the pipe 80 and maintaining the magnetic flux modulation function of the iron core 60 can be obtained.

In the example of FIG. 2B, the dust core 70 forming the end of the iron core 60 on one side in the first direction is the one-side dust core 71, and the dust core 70 forming the other end is the other-side dust core. It is the magnetic core 72 . The one-side powder magnetic core 71 is arranged on one side in the first direction of the steel plate laminate 79 , and the other-side powder magnetic core 72 is arranged on the other side of the steel plate laminate 79 in the first direction. According to the above configuration, by providing one-side dust core 71 , it is possible to suppress leakage magnetic flux that tends to occur at one end of iron core 60 , and to suppress generation of eddy current in iron core 60 . Therefore, the temperature rise of the iron core 60 can be suppressed. Further, by providing the other side powder magnetic core 72, the temperature rise of the iron core 60 can be suppressed for the same reason. At least one powder magnetic core 70 may be further arranged between the one-side powder magnetic core 71 and the steel plate laminate 79 . Similarly, at least one dust core 70 may be further arranged between the other side dust core 72 and the steel plate laminate 79 . In either embodiment, the above advantages are obtained.

Also, the thickness of the pipe 80 according to an embodiment of the present disclosure is 10% or less of the minimum value of the inner diameter of the dust core hole 75 . According to the above configuration, the pipe 80 can be made thinner, so heat exchange between the air flowing in the inner space of the pipe 80 and the dust core 70 can be promoted, and an improvement in the cooling performance of the core unit 10 is expected. can.

<3. Insulator 110>
Returning to FIG. 1 , the core unit 10 according to an embodiment of the present disclosure further includes insulators 110 arranged so as to be stacked on the ends of the core 60 in the first direction. The insulator 110 forms an end of the core unit 10 in the first direction. The insulator 110 illustrated in FIG. 1 is plate-shaped with a thickness in the first direction. As an example, the material forming the insulator 110 is Fiber Reinforced Plastics (FRP), more specifically Glass Fiber Reinforced Plastics (GFRP). As another example of the material forming the insulator 110, a resin material, a ceramic material, or the like may be employed. In the example of FIG. 1, the insulators 110 are arranged on both sides of the iron core 60 in the first direction. An insulator hole 115 penetrating in the first direction is formed in the central portion of each insulator 110 , and each insulator hole 115 faces the insertion hole 68 of the iron core 60 in the first direction. A pipe 80 according to an embodiment of the present disclosure is inserted not only into the insertion hole 68 but also into the insulator hole 115 . More specifically, as an example, the end of the pipe 80 in the first direction is accommodated in the insulator hole 115 . That is, the pipe 80 does not protrude from the insulator hole 115 to the side opposite to the core unit 10 . The fit between pipe 80 and insulator bore 115 may be an interference fit, an intermediate fit, or a clearance fit.

According to the above configuration, by inserting the pipe 80 into the insulator hole 115 of the insulator 110 arranged so as to be stacked at the end of the iron core 60 , the pipe 80 is less likely to come off from the dust core hole 75 . Therefore, the mechanical strength of the core unit 10 is improved. In addition, by providing insulator 110 , it is possible to suppress leakage magnetic flux that tends to occur at the ends of iron core 60 in the first direction, and to suppress generation of eddy current in iron core 60 . Therefore, the temperature rise of the iron core 60 can also be suppressed.
In addition, even if the dust core 70 is damaged, the insulator 110 stacks on the end of the iron core 60 to prevent the flake dust core 70 from falling off the iron core 60. be able to.

Also, the one end 87 of the pipe 80 on one side in the first direction may be located on the opposite side (that is, the other side) of the end 111 of the insulator 110 on the one side (FIGS. 3 and 4). 5). In an embodiment in which the core unit 10 is incorporated into a rotor 30 (see FIG. 7) described later, the insulator 110 is sandwiched between the end ring 31, which is a component of the rotor 30, and the core 60 described above. In this respect, the one end 87 of the pipe 80 is positioned on the other side of the end 111 of the insulator 110, so that the one end 87 accommodated in the insulator hole 115 and the end ring 31, which may be made of metal, are separated from each other. contact is avoided. As a result, unintentional conduction between the iron core 60 and the end ring 31 can be avoided.
However, the present disclosure does not exclude embodiments in which the end 87 of the pipe 80 and the end 111 of the insulator 110 are co-located with each other in the first direction (see FIG. 4). Also, the present disclosure does not exclude embodiments in which one end 87 of pipe 80 is located to one side of end 111 of insulator 110 (not shown).

<4. Joint structure between iron core 60A (60) and pipe 80>
FIG. 3 is a schematic cross-sectional view showing a joint structure between an iron core 60A (60) and a pipe 80 according to an embodiment of the present disclosure. Insulators 110 are stacked in the first direction on the core 60A shown in the figure.

The dust core 70 has a dust core inner peripheral surface 76 defining a dust core hole 75, the insulator 110 has an insulator inner peripheral surface 116 defining an insulator hole 115, and the pipe 80 has a pipe outer peripheral surface. 89. The pipe 80 illustrated in FIG. 3 is inserted into the dust core hole 75 and the insulator hole 115 . The pipe outer peripheral surface 89 has a portion that axially overlaps the dust core inner peripheral surface 76 and a portion that axially overlaps the insulator inner peripheral surface 116 . Note that the axial direction of the pipe 80 coincides with the first direction.

In the example of FIG. 3, the adhesive 9 is interposed between the inner peripheral surface 76 of the dust core and the outer peripheral surface 89 of the pipe. In the example shown in the figure, the adhesive 9 is present over substantially the entire length in one direction of the iron core 60A. The adhesive 9 is interposed between the outer peripheral surface 89 and the outer peripheral surface 89 . However, the present disclosure is not limited to the adhesive 9 intervening only between the pipe outer peripheral surface 89 and the dust core inner peripheral surface 76 . The adhesive 9 may be interposed between the insulator inner peripheral surface 116 and the pipe outer peripheral surface 89 as illustrated in the figure. Moreover, the adhesive 9 preferably has insulating properties, and more preferably has insulating properties and non-magnetism.

According to the above configuration, since the adhesive 9 is interposed between the outer peripheral surface 89 of the pipe and the inner peripheral surface 76 of the dust core, it is possible to suppress the fall of the piece-shaped dust core 70 caused by chipping from the iron core 60. . Further, since the outer peripheral surface 89 of the pipe and the inner peripheral surface 76 of the dust core can be brought into close contact with each other through the adhesive 9, the thermal conductivity from the dust core 70 to the pipe 80 can be further improved.
Note that the core unit 10 may not include the insulator 110 . Also, the adhesive 9 may be placed on the iron core 60B (FIG. 2B) instead of the iron core 60A. More specifically, the adhesive 9 is arranged between the inner peripheral surface forming the insertion hole 68B (that is, the powder magnetic core inner peripheral surface 76 and the steel plate inner peripheral surface 176 described later) and the pipe outer peripheral surface 89. may The above advantages are also obtained in this embodiment.

FIG. 4 is a schematic diagram showing the detailed structure of a pipe 80A (80), which is an example of the pipe 80. As shown in FIG. The pipe 80A in the figure is inserted into the insertion hole 68A of the iron core 60A. A pipe outer peripheral surface 89A (89) of the pipe 80A has at least one of an outer peripheral surface concave portion 181 and an outer peripheral surface convex portion 183. As shown in FIG. In the figure, both the outer peripheral surface recessed portion 181 and the outer peripheral surface convex portion 183 are provided. Outer peripheral surface convex portions 183 are provided at intervals in the first direction. The outer peripheral surface concave portion 181 or the outer peripheral surface convex portion 183 is formed by subjecting the pipe outer peripheral surface 89A to machining such as blasting, knurling, or carving. At least one of the outer peripheral surface concave portion 181 and the outer peripheral surface convex portion 183 may be formed over the entire surface of the pipe outer peripheral surface 89, or may be formed on the outer peripheral surface 89A of the pipe along the inner peripheral surface 76 of the dust core in the axial direction. It may be formed only in a portion overlapping with . Further, only one of the outer peripheral surface recessed portion 181 and the outer peripheral surface convex portion 183 may be provided on the pipe outer peripheral surface 89A. Furthermore, the outer peripheral surface convex portion 183 may be a separate member from the pipe outer peripheral surface 89 . According to the above configuration, at least one of the outer peripheral surface concave portion 181 and the outer peripheral surface convex portion 183 is provided, so that the adhesive 9 interposed between the pipe outer peripheral surface 89A (89) and the dust core inner peripheral surface 76 is removed. increase in volume. As a result, it is possible to further prevent the piece-shaped dust core 70 caused by the chipping from falling off the iron core 60A (60).

Although not an essential component of the present disclosure, the pipe 80A (80) has a pipe inner peripheral surface 86 and at least one of an inner peripheral surface convex portion 861 or an inner peripheral surface concave portion 863 provided on the pipe inner peripheral surface 86. and may be further provided. In the example of FIG. 4, both the inner peripheral surface convex portion 861 and the inner peripheral surface concave portion 863 are provided. The inner peripheral surface convex portion 861 is, for example, a fin separate from the pipe inner peripheral surface 86 and extends over the entire circumferential length of the pipe 80A. A plurality of inner peripheral surface convex portions 861 are arranged at intervals along the axial direction. The inner peripheral surface concave portion 863 is a groove provided in the pipe inner peripheral surface 86 and extends over the entire circumferential length of the pipe 80A. A plurality of inner peripheral recesses 863 are arranged at intervals along the axial direction. The inner peripheral surface convex portion 861 is preferably provided at a portion of the pipe inner peripheral surface 86 that axially overlaps the insertion hole 68A of the iron core 60A, and the inner peripheral surface concave portion 863 is the same. Only one of the inner peripheral surface convex portion 861 and the inner peripheral surface concave portion 863 may be provided on the pipe inner peripheral surface 86 . Further, an inner peripheral surface convex portion 861 or an inner peripheral surface concave portion 863 may be provided at a portion of the pipe inner peripheral surface 86 that overlaps the insulator inner peripheral surface 116 in the axial direction (in the example of FIG. An inner peripheral surface recessed portion 863 is provided at that portion of the peripheral surface 86). The pipe 80 provided with at least one of the inner peripheral surface convex portion 861 and the inner peripheral surface concave portion 863 is, for example, a rifle tube.

According to the above configuration, heat exchange between the pipe inner peripheral surface 86 and the air is promoted, so the cooling performance of the iron core 60A (60) can be improved. The present disclosure is not limited to the fact that the pipe 80A is inserted into the insertion hole 68A of the iron core 60A. Pipe 80A may be inserted into insertion hole 68B of core 60B (see FIG. 2B). In this case, the inner peripheral surface convex portion 861 and the inner peripheral surface concave portion 863 overlap in the axial direction with the inner peripheral surface (the powder magnetic core inner peripheral surface 76 and the steel plate inner peripheral surface 176 described later) forming the insertion hole 68B. may be placed in

<5. Joint structure between iron core 60B (60) and pipe 80>
FIG. 5 is a schematic cross-sectional view showing a joint structure between an iron core 60B (60) and a pipe 80 according to another embodiment of the present disclosure. Insulators 110 are stacked in the first direction on the core 60B shown in the figure. As described above, core 60B includes a steel plate stack 79 that includes a plurality of steel plates 77 . Each steel plate 77 has a steel plate inner peripheral surface 176 defining a steel plate hole 78 penetrating in the first direction.

The pipe 80 is inserted into the insertion hole 68B (68) and the insulator hole 115. As shown in FIG. The pipe outer peripheral surface 89 of the pipe 80 exemplified in FIG. and a portion that overlaps in direction.

In this example, an insulating member 120 interposed at least between the pipe outer peripheral surface 89 and the steel plate inner peripheral surface 176 is further arranged. The insulating member 120 exemplified in FIG. 116. The insulating member 120 may be formed by insulating the pipe outer peripheral surface 89, or may be a member formed of a resin material, a ceramic material, or a rubber material.

In general, a steel plate 77 having a steel plate inner peripheral surface 176 is obtained by punching a steel plate material (not shown) having an insulating coating formed on the outer surface thereof. Therefore, an insulating coating is not formed on the inner peripheral surface 176 of the steel plate. Therefore, if an eddy current is generated in one of the plurality of laminated steel plates 77 , the current may flow to the other steel plates 77 via the steel plate inner peripheral surface 176 . In other words, the current may flow through the steel plate laminate 79 in the first direction. In this respect, according to the above configuration, the insulator 110 is arranged between the outer peripheral surface 89 of the pipe and the inner peripheral surface 176 of the steel plate, so that the electric current generated in any one of the steel plates 77 moves the stacked steel plate 79 in the first direction. can be prevented from flowing into

<6. Slit 85 of pipe 80>
6A to 6C are schematic diagrams showing pipes 81, 82, 83 (80) as an example of pipe 80. FIG. The pipes 81-83 illustrated in FIGS. 6A-6C include peripheral walls 84A, 84B, 84C (84) and slits 85A, 85B, 85C (85) penetrating the peripheral wall 84 in the radial direction of the pipe 80. As shown in FIG. The slits 85A, 85B, 85C extend along the first direction. More specifically, the slits 85A and 85B linearly extend in the first direction, and the slit 85C spirally extends in the first direction.

Also, as illustrated in FIGS. 6A and 6C, the slits 85A and 85C (85) are formed from one end to the other end in the first direction of the pipes 81 and 83 (80). It depends. That is, the slits 85A and 85C are open on one side and the other side in the first direction. Also, as illustrated in FIG. 6B, the slit 85B (85) is open to one side in the first direction, but is not open to the other side of the slit 85B. In this case, the other end of the slit 85B in the first direction is located on one side of the other end of the pipe 82 (80). Although detailed illustration is omitted, both ends of the slit 85 in the first direction may not be open in the first direction. In other words, both ends of the slit 85 in the first direction may be located on the central side of the pipe 80 in the first direction with respect to both ends of the pipe 80 in the first direction. Moreover, it is preferable that the number of slits 85 formed in the pipe 80 is one, thereby simplifying the structure of the pipe 80 .

According to the above configuration, since the slit 85 is provided, the pipe 80 can be inserted into the insertion hole 68 in a state of being compressed to the axial center side in the manufacturing process of the core unit 10 . After the insertion is completed, the compressed pipe 80 spreads away from the axial center, and at least a part of the peripheral wall 84 of the pipe 80 extends to the inner peripheral surface (more specifically, as an example, dust powder) forming the insertion hole 68 It presses against the magnetic core inner peripheral surface 76). As a result, the heat conductivity from the dust core 70 to the pipe 80 is improved, so that the cooling performance of the core unit 10 is further improved.

<7. Illustration of rotor 30 incorporating core unit 10>
7 and 8 illustrate a rotor 30 incorporating the core unit 10. FIG. The rotor 30 is configured to rotate in a circumferential direction, which is a direction perpendicular to the first direction, and is connected to, for example, a rotating shaft 5 that constitutes the magnetic geared electric machine 1 (see FIG. 9) (magnetically geared The outline of the configuration of the electric machine 1 will be described later). The first direction coincides with the axial direction of the rotor 30, and the rotating shaft 5 extends in the first direction. In the following description, the radial direction with respect to the axis of the rotor 30 may be simply referred to as "radial direction".

FIG. 7 is a schematic diagram of a rotor 30 according to one embodiment. The rotor 30 comprises a ring unit 50 extending in the circumferential direction. Ring unit 50 includes a plurality of core units 10 and a plurality of non-magnetic bodies 52 . The plurality of core units 10 and the plurality of non-magnetic bodies 52 are alternately arranged in the circumferential direction, and each core unit 10 is sandwiched between a pair of non-magnetic bodies 52 located on both sides in the circumferential direction. In the example shown in the figure, a pair of end rings 31 as components of the rotor 30 are provided at both ends of the ring unit 50 in the first direction. The end ring 31 has a plate shape extending in the circumferential direction and having a thickness in the first direction.

The rotor 30 further includes a pair of flanges 41 connected to both ends of the ring unit 50 in the first direction, and each flange 41 is configured to be connected to the rotating shaft 5 . A detailed example of the configuration of the flange 41 is as follows. The flange 41 includes a ring portion 42 extending in the circumferential direction, a plurality of extension portions 47 extending radially inward from the ring portion 42 , and a shaft connection portion 48 connected to the inner end portion of the extension portions 47 . and The ring portion 42 of this example has a plate shape having a thickness in the first direction, and is connected to the end portion of the ring unit 50 via the end ring 31 (that is, the flange 41 is indirectly connected to the end portion of the ring unit 50). directly connected.). The shaft connecting portion 48 has a cylindrical shape along the first direction, and the inner peripheral surface of the shaft connecting portion 48 is connected to the rotating shaft 5 (see FIG. 9).

Further, the ring portion 42 of the flange 41 is formed with at least one flange hole 43 communicating with the inner space of each pipe 80 (see FIGS. 2A and 2B) of the core unit 10 in the first direction. In the example of FIG. 7, the flange hole 43 faces a plurality of end ring holes (not shown) formed in the end ring 31 in the first direction. It faces the insulator hole 115 (see FIG. 1) in the first direction. As a result, the flange hole 43 communicates with the inner space of the pipe 80, and air can flow through the inner space of the pipe 80 as the rotor 30 rotates.

To explain a more detailed configuration example, at least one flange hole 43 is a plurality of flange holes 43 arranged at intervals in the circumferential direction, and the plurality of flange holes 43 are respectively connected to a plurality of end ring holes and a first ring hole. facing direction. However, the present disclosure is not limited to the above configuration. The ring portion 42 according to another embodiment may be a frame-shaped (in other words, hollow) ring extending in the circumferential direction instead of being a plate-shaped ring extending in the circumferential direction. In this case, the single open hole formed inside the frame corresponds to the flange hole 43 . Therefore, the number of flange holes 43 is one. Also, the rotor 30 may not have the pair of end rings 31 . In this case, the ring portion 42 may be directly connected to the end portion of the ring unit 50 . When the one end 87 of the pipe 80 is positioned on the other side in the first direction from the end 111 of the insulator 110 (see FIGS. 3 and 5), the one end 87 of the pipe 80 and the ring which may be made of metal By avoiding contact with the portion 42, unintended conduction between the iron core 60 and the ring unit 50 can be avoided.

FIG. 8 is a schematic diagram showing part of the configuration of the ring unit 50 according to one embodiment of the present disclosure. In the figure, the circumferential direction is shown to match the lateral direction of the paper. The non-magnetic body 52 is made of FRP as described above. FRP may be, for example, glass fiber reinforced plastics (GFRP) or carbon fiber reinforced plastics (CFRP).

Further, the ring unit 50 has a flexible member 150 interposed between the iron core 60 and the non-magnetic body 52 . The flexible member 150 is a member that has a Young's modulus smaller than that of the iron core 60 and is elastically deformable in the first direction. The flexible member 150 is made of rubber, resin, or elastomer, for example. Flexible member 150 is preferably in the form of a sheet. In addition, in the example shown in the figure, the flexible member 150 is interposed between the iron core 60 and the non-magnetic body 52 over the entire length of the iron core 60 in the first direction.

According to the above configuration, since the non-magnetic body 52 is made of a fiber-reinforced composite material, the non-magnetic body 52 can ensure insulation, and the weight and rigidity of the rotor 30 can be reduced. On the other hand, the coefficient of linear expansion of the non-magnetic body 52 formed of FRP is smaller than that of the dust core 70 . Therefore, when the temperature of the rotor 30 having the structure in which the dust core 70 and the non-magnetic material 52 are in direct contact increases, the non-magnetic material 52 extends more than the dust core 70 in the first direction. As a result, tensile stress resulting from the expansion of the non-magnetic material 52 is generated as thermal stress in the powder magnetic core 70, and the powder magnetic core 70, which has relatively low mechanical strength, may be damaged. In other words, there is a possibility that the dust core 70 will be damaged. In this regard, according to the above configuration, the flexible member 150 has a portion in contact with the non-magnetic body 52 and a portion in contact with the iron core 60, and it is possible to make the extension amounts of the two portions different in the first direction. becomes. That is, the flexible member 150 can reduce the thermal stress generated in the dust core 70 . Thereby, the rotor 30 can suppress the destruction of the dust core 70 .

Flexible member 150 according to one embodiment is formed from a thermoplastic elastomer. According to the above configuration, since the elastomer has an adhesive function, it is not necessary to prepare a separate adhesive material for joining the iron core 60 , the non-magnetic body 52 and the flexible member 150 . Therefore, the configuration of the rotor 30 can be simplified.

Furthermore, in the example of FIG. 3, flexible members 151 and 152 made of the same material as the flexible member 150 are arranged on the radial outer surface and inner surface of the core unit 10, respectively. The flexible members 150 to 152 of this example are sheet materials made of an elastomer integrally formed, and are provided so as to wrap the core unit 10 . Further, the rotor 30 in the figure further includes an outer cover 55A that covers the ring unit 50 from the outside in the radial direction, and an inner cover 55B that covers the ring unit 50 from the inside in the radial direction. The outer cover 55A and the inner cover 55B of this example are prepreg materials obtained by impregnating a fiber base material such as CFRP with a thermosetting resin. The outer cover 55A and the inner cover 55B are joined to the ring unit 50 by adhering them to the flexible members 151 and 152 via the adhesive layer 59 . The ring unit 50 can be reinforced by providing the outer cover 55A and the inner cover 55B over the entire circumferential length of the ring unit 50 .

<8. Illustration of rotor 30 incorporating core unit 10>
FIG. 9 is a schematic illustration of a magnetically geared electric machine 1 with a rotor 30. FIG. The magnetic geared electric machine 1 comprises a rotating shaft 5 extending in a first direction and the rotor 30 comprises a pair of flanges 41 as described above. Each flange 41 is directly connected to the rotating shaft 5 . The magnetic geared electric machine 1 further includes a magnet rotor 15 supported by the rotating shaft 5 between the pair of flanges 41 via bearings. The magnet rotor 15 includes a plurality of rotor magnets 19 arranged in the circumferential direction inside the core unit 10 . The magnetic geared electric machine 1 also includes a stator 20 fixed radially outside the core unit 10 . The stator 20 includes a plurality of stator magnets 29 arranged in a circumferential direction, a stator yoke 25 supporting the plurality of stator magnets 29, and a coil 27 as an armature coil wound around the stator yoke 25. including. Coil 27 is then electrically connected to power system 6 . In the magnetic geared electric machine 1 having the structure described above, the core unit 10 functions as a pole piece unit, and the rotor 30 functions as a pole piece rotor.

The rotating shaft 5 is connected to an external rotating device 7 . The magnetic geared electric machine 1 is, for example, a magnetic geared motor that receives power supply from a power system 6 to drive an external rotating device 7 . The operating principle of the magnetic geared electric machine 1 as a magnetic geared motor is as follows. A rotating magnetic field generated by energization of the coil 27 causes the magnet rotor 15 to rotate. The relative positional relationship of the plurality of core units 10 with respect to the plurality of rotor magnets 19 and the plurality of stator magnets 29 changes, the magnetic flux between the magnet rotor 15 and the stator 20 is modulated, and the rotor 30 It rotates together with the rotating shaft 5 . Torque is transmitted from the rotating shaft 5 to the external rotating device 7 so that the external rotating device 7 can be driven.

The magnetic geared electric machine 1 may be a magnetic geared generator instead of the magnetic geared motor. In this case, a configuration in which the external rotating device 7 drives the rotating shaft 5 may be adopted. When the rotor 30 rotates together with the rotating shaft 5, the relative positional relationship of the plurality of core units 10 with respect to the plurality of rotor magnets 19 and the plurality of stator magnets 29 changes, and the magnet rotor 15 rotates. A current is generated in the coil 27 by electromagnetic induction caused by the rotation of the rotor 30 and the magnet rotor 15 , and power is supplied to the power system 6 .

The rotor 30 including the core unit 10 can improve the cooling performance for the reason described above. In addition, since at least one of centrifugal force, vibration, and electromagnetic force acts on the iron core unit 10 as the magnetic geared electric machine 1 operates, there is a possibility that the dust core 70 may be damaged. Even in this case, the rotor 30 can prevent the dust core 70 from falling off the core unit 10 for the reason described above.

<9. Others>
The present disclosure is not limited to incorporating the core unit 10 into the rotor 30 . The core unit 10 may be incorporated into the stator 20 of the magnetic geared electric machine 1 described above. Alternatively, the core unit 10 may be incorporated in a stator (not shown) that constitutes the axial gap motor.

<10. Summary>
The contents described in the several embodiments described above can be understood, for example, as follows.

1) A core unit (10) according to at least one embodiment of the present disclosure,
an iron core (60) including at least one dust core (70) having a dust core hole (75) penetrating in a first direction;
a pipe (80) extending in the first direction and inserted into the dust core hole;
Prepare.

According to the above configuration 1), the powder magnetic core hole into which the pipe is inserted is formed in the powder magnetic core, so that the air flowing through the inner space of the pipe can cool the iron core. As a result, it is possible to suppress the temperature rise of the iron core caused by, for example, the generation of eddy currents or the energization of the armature coils. Further, for example, if a tensile stress occurs in the first direction, the dust core may be damaged. In this respect, according to the configuration 1) above, since the pipe is inserted into the dust core hole, even if the dust core is damaged, it is possible to prevent the piece-shaped dust core from falling off from the iron core. Therefore, an iron core unit that can maintain the shape of the dust core and improve the cooling performance of the iron core is realized.

2) In some embodiments, the core unit according to 1) above,
The pipe is
a peripheral wall (84);
a slit (85) radially penetrating the peripheral wall and extending along the first direction;
including.

According to the above configuration 2), since the slit is provided, the pipe can be inserted into the insertion hole in a state of being compressed toward the axial center in the manufacturing process of the core unit. After the insertion is completed, the compressed pipe spreads away from the axial center, and at least a part of the peripheral wall of the pipe presses against the inner peripheral surface of the dust core. This improves the thermal conductivity from the dust core to the pipe, further improving the cooling performance of the core unit.

3) In some embodiments, the core unit according to 1) or 2) above,
It further comprises an adhesive (9) interposed between a pipe outer peripheral surface (89) of the pipe and a dust core inner peripheral surface (76) of the dust core defining the dust core hole.

According to the above configuration 3), since the adhesive is interposed between the outer peripheral surface of the pipe and the inner peripheral surface of the dust core, it is possible to suppress the fall of the flake-shaped dust core caused by chipping from the iron core. In addition, since the outer peripheral surface of the pipe and the inner peripheral surface of the dust core can be brought into close contact with each other via the adhesive, the thermal conductivity from the dust core to the pipe can be further improved.

4) In some embodiments, the core unit according to 3) above,
The pipe outer peripheral surface has at least one of an outer peripheral surface concave portion (181) or an outer peripheral surface convex portion (183).

According to the above configuration 4), since the amount of the adhesive interposed between the outer peripheral surface of the pipe and the inner peripheral surface of the dust core increases, it is possible to prevent the flake-shaped dust core from falling off from the iron core. can be suppressed further.

5) In some embodiments, the core unit according to any one of 1) to 4) above,
further comprising an insulator (110) arranged so as to be stacked at an end portion of the iron core in the first direction, the insulator having an insulator hole (115) penetrating in the first direction;
The pipe is inserted into the insulator hole.

According to the above configuration 5), by inserting the pipe into the insulator hole of the insulator arranged so as to be stacked at the end of the iron core, the pipe can be made difficult to come off from the dust core hole. Therefore, the mechanical strength of the core unit is improved. In addition, by providing the insulator, it is possible to suppress leakage magnetic flux that tends to occur at the ends of the iron core in the first direction, and to suppress the occurrence of eddy current in the iron core. Therefore, it is possible to suppress the temperature rise of the iron core.

6) In some embodiments, the core unit of 5) above,
One end (87) of the pipe on one side in the first direction is located on the opposite side of the one side from the end (111) of the insulator on the one side.

According to the configuration 6) above, contact between one end of the pipe and a component (for example, the end ring 31) of another unit (for example, the rotor 30) to which the core unit is assembled is avoided. This makes it possible to avoid unintentional conduction between the component and the iron core.

7) In some embodiments, the core unit according to any one of 1) to 6) above,
The iron core includes a plurality of the dust cores stacked in the first direction,
The pipe is inserted into the dust core hole of each of the dust cores.

According to the above configuration 7), since the iron core includes a plurality of dust cores, each dust core forming the iron core can be miniaturized. This makes it possible to simplify the work of inserting each dust core into a pipe in the core assembly process. In addition, by realizing the miniaturization of the dust core, the molding pressure of the molding machine used in the molding process of the dust core can be reduced, and the manufacture of the dust core can be facilitated.

8) In some embodiments, the core unit according to any one of 1) to 7) above,
The core is
a steel plate laminate (79) having a plurality of steel plates (77) laminated in the first direction;
a one-side powder magnetic core (71) that is arranged on one side of the steel plate laminate in the first direction and that forms an end portion on the one side of the iron core;
further includes

According to the above configuration 8), since the end portion of the iron core in the first direction is formed by the one-side powder magnetic core, leakage magnetic flux that tends to occur at the one-side end portion of the iron core can be suppressed, and in the iron core It is possible to suppress the occurrence of eddy currents. Therefore, the temperature rise of the iron core can be suppressed.

9) In some embodiments, the core unit according to any one of 1) to 8) above,
The pipe is longer than the core in the first direction and is inserted from one end of the core to the other end in the first direction.

According to the configuration 9) above, since the pipe is inserted so as to penetrate the iron core, the pipe can support the iron core more firmly, and the mechanical strength of the iron core unit can be improved.

10) In some embodiments, the core unit according to any one of 1) to 9) above,
The pipe is made of non-magnetic material.

According to the above configuration 10), the generation of hysteresis loss due to the magnetization of the pipe can be suppressed, and the magnetic flux modulation function of the iron core can be maintained.

11) In some embodiments, the core unit of 10) above,
The pipe is made of a non-magnetic metallic material.

According to the configuration 11) above, the thermal conductivity of the pipe is improved, so that the thermal conductivity from the dust core to the pipe can be further improved.

12) In some embodiments, the core unit of any one of 1) to 11) above,
The core is
including a plurality of steel plates (77) stacked in the first direction, each having a steel plate hole (78) penetrating in the first direction,
The core unit further includes an insulating member (120) interposed between a pipe outer peripheral surface (89) of the pipe and a steel plate inner peripheral surface (176) of the steel plate defining the steel plate hole.

In general, since an insulating coating is not formed on the inner peripheral surface of the steel plate, if an eddy current is generated in one of the steel plates, the current may flow through the steel plate laminate in the first direction via the inner peripheral surface of the steel plate. There is In this regard, according to the configuration of 12) above, since the insulating member is arranged between the outer peripheral surface of the pipe and the inner peripheral surface of the steel plate, the current generated in any one of the steel plates flows through the steel plate laminate in the first direction. can be suppressed.

13) In some embodiments, the core unit of any one of 1) to 12) above,
The pipe is
a pipe inner peripheral surface (86);
At least one of an inner peripheral surface convex portion (861) or an inner peripheral surface concave portion (863) provided on the inner peripheral surface of the pipe;
further provide.

According to the above configuration 13), the heat exchange between the inner peripheral surface of the pipe and the air is promoted, so that the cooling performance of the iron core can be improved.

14) A rotor (30) according to at least one embodiment of the present disclosure comprises:
A plurality of core units (10) according to any one of 1) to 12) above, and a plurality of non-magnetic bodies arranged alternately with the plurality of core units in a circumferential direction orthogonal to the first direction. a ring unit (50) comprising (52);
a pair of flanges (34) respectively connected to both ends of the ring unit in the first direction, the pair of flanges being respectively configured to be connected to a rotating shaft extending in the first direction; ,
with
Each flange is formed with at least one flange hole (43) that communicates with the inner space of the pipe (80) of each of the plurality of core units.

According to configuration 14) above, for the same reason as above 1), a rotor in which the shape of the dust core can be maintained and the cooling performance of the iron core is improved is realized.

15) In some embodiments, the rotor (30) of 14) above, comprising:
Each non-magnetic body is formed of a fiber-reinforced composite material,
The ring unit further includes a flexible member (150) interposed between the iron core and the non-magnetic body.

According to the above configuration 14), since the non-magnetic material is a fiber-reinforced composite material, the insulating properties of the non-magnetic material are ensured, and the weight and rigidity of the rotor can be reduced. On the other hand, the coefficient of linear expansion of the non-magnetic material formed by the fiber-reinforced composite material is smaller than that of the dust core. Therefore, when the temperature of the rotor having the structure in which the dust core and the non-magnetic material are in direct contact increases, the non-magnetic material extends in the first direction more than the dust core. As a result, the tensile stress resulting from the expansion of the non-magnetic material is generated in the powder magnetic core as thermal stress, and the powder magnetic core with relatively low mechanical strength may be damaged. That is, there is a possibility that defects in the dust core may occur. In this regard, according to the configuration of 15) above, the flexible member has a portion that contacts the non-magnetic material and a portion that contacts the iron core, and it is possible to make different amounts of stretching in the first direction between the two portions. becomes. That is, the flexible member can reduce the thermal stress generated in the dust core. Thereby, the rotor can suppress the destruction of the dust core.

16) In some embodiments, the rotor of 15) above,
The flexible member is made of elastomer.

According to the configuration 16) above, since the elastomer includes an adhesive function, it is not necessary to prepare a separate adhesive material for joining the iron core, the non-magnetic body, and the flexible member. Therefore, the configuration of the rotor can be simplified.

5: Rotating shaft 9: Adhesive 10: Iron core unit 30: Rotor 41: Flange 43: Flange hole 50: Ring unit 52: Non-magnetic material 60: Iron core 70: Dust core 71: One side dust core 75: Dust Magnetic core hole 76 : Dust core inner peripheral surface 77 : Steel plate 78 : Steel plate hole 79 : Steel plate laminate 80 (80A, 81 to 83) : Pipe 84 : Peripheral wall 85 : Slit 86 : Pipe inner peripheral surface 87 : One end 89 : Pipe Outer peripheral surface 110 : Insulator 111 : End 115 : Insulator hole 120 : Insulating member 150 : Flexible member 176 : Steel plate inner peripheral surface 181 : Outer peripheral surface concave portion 183 : Outer peripheral surface convex portion 861 : Inner peripheral surface convex portion 863 : Inner peripheral recess

Claims (14)

an iron core including at least one powder magnetic core having a powder magnetic core hole penetrating in a first direction;
a pipe extending in the first direction and inserted into the dust core hole;
with
The pipe is
a peripheral wall;
a slit radially penetrating the peripheral wall and extending along the first direction;
including
The slit is open to at least one side in the first direction,
core unit. Further comprising an adhesive interposed between the pipe outer peripheral surface of the pipe and the dust core inner peripheral surface of the dust core defining the dust core hole,
The core unit according to claim 1 . The outer peripheral surface of the pipe has at least one of an outer peripheral surface concave portion and an outer peripheral surface convex portion,
The core unit according to claim 2 . an iron core including at least one powder magnetic core having a powder magnetic core hole penetrating in a first direction;
a pipe extending in the first direction and inserted into the dust core hole;
a one-side insulator disposed so as to be stacked on one end of the iron core in the first direction, the one-side insulator having an insulator hole penetrating in the first direction ;
with
the pipe is inserted into the insulator hole such that one end of the pipe on the one side in the first direction is located on the other side in the first direction with respect to the end of the one-side insulator ;
core unit. The iron core includes a plurality of the dust cores stacked in the first direction,
The pipe is inserted into the dust core hole of each of the dust cores,
The core unit according to claim 1 or 4 . The core is
a steel plate laminate having a plurality of steel plates laminated in the first direction;
a one-side powder magnetic core that is arranged on one side in the first direction relative to the steel plate laminate and that forms an end portion on the one side of the iron core;
further comprising
The core unit according to claim 1 or 4 . The pipe is longer than the core in the first direction, and is inserted from one end of the core to the other end in the first direction,
The core unit according to claim 1 or 4 . The pipe is made of a non-magnetic material,
The core unit according to claim 1 or 4 . The pipe is made of a non-magnetic metallic material,
The core unit according to claim 8 . The core is
A plurality of steel plates stacked in the first direction, wherein a plurality of steel plates each having a steel plate hole penetrating in the first direction are formed,
The core unit further comprises an insulating member interposed between the pipe outer peripheral surface of the pipe and the steel plate inner peripheral surface of the steel plate defining the steel plate hole,
The core unit according to claim 1 or 4 . The pipe is
the inner peripheral surface of the pipe;
At least one of an inner peripheral surface convex portion or an inner peripheral surface concave portion provided on the inner peripheral surface of the pipe;
further comprising
The core unit according to claim 1 or 4 . a plurality of iron cores each including: at least one dust core having a dust core hole penetrating in a first direction; and a pipe extending in the first direction and inserted into the dust core hole and a plurality of non-magnetic bodies arranged alternately with the plurality of core units in a circumferential direction perpendicular to the first direction;
a pair of flanges respectively connected to both ends of the ring unit in the first direction, the pair of flanges being configured to be connected to a rotating shaft extending in the first direction;
with
At least one flange hole communicating with the inner space of the pipe of each of the plurality of core units is formed in each of the flanges,
rotor. Each non-magnetic body is formed of a fiber-reinforced composite material,
The ring unit further comprises a flexible member interposed between the iron core and the non-magnetic material,
A rotor according to claim 12 . The flexible member is made of an elastomer,
A rotor according to claim 1-3 .

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