JP7402123B2 - Rotor, axial gap type transverse flux type rotating electric machine, and assembly method - Google Patents

Description

The present invention relates to a rotor, etc. of an axial gap type transverse flux type rotating electric machine.

Transverse flux motors (TFM) are known as one of the classifications of motors that are rotating electric machines. A transverse flux motor is a high torque density motor proposed by Weh in 1986 (see, for example, Non-Patent Document 1). In recent years, various research and developments have been carried out in fields where torque density is important, and a three-phase motor with three windings was constructed based on the motor proposed by Weh, and it was possible to drive it with a normal three-phase inverter. A radial gap type transverse flux motor has been proposed (for example, see Patent Document 1 and Patent Document 2).

H. Weh and H. May, “Achievable force densities for permanent magnet excited machines in new configuration,” in International Conference on Electrical Machines - ICEM, Munchen, Sept. 1986, pp. 1107-1111.

JP2015-228730A JP 2019-129563 Publication

The basic structure of the rotor of an axial gap type transverse flux motor is such that permanent magnets and magnetic cores are alternately arranged in the circumferential direction. Since magnetic force and centrifugal force act on the permanent magnet and the magnetic core, they must be firmly connected and fixed to each other.

For a relatively small axial gap type transverse flux motor, a method of fixing the permanent magnet and the magnetic core with adhesive can be adopted. However, especially when an axial gap type transverse flux motor is employed as a main electric motor for a railway vehicle, the rotor becomes large, so the magnetic force and centrifugal force that act on it also become relatively large. Moreover, the inside of the motor case becomes relatively hot. Adhesives generally deteriorate more quickly in high-temperature environments, and there is a high possibility that they will not be able to withstand long-term use. Therefore, a new method of fixing permanent magnets and magnetic cores that does not rely solely on adhesives is desired.

Note that these problems are not limited to the case where the axial gap type transverse flux type rotating electric machine is used as an electric motor (electric motor), but also apply when the axial gap type transverse flux type rotating electric machine is used as a generator.

An object of the present invention is to provide a new technique for fixing permanent magnets and magnetic cores related to the rotor of an axial gap type transverse flux rotating electric machine.

A first invention for solving the above-mentioned problems is a rotor for an axial gap type transverse flux rotating electrical machine, which includes a disk body and a permanent rotor disposed at intervals in the circumferential direction of the disk surface of the disk body. A magnet, a support for fixing the permanent magnet to the disk body, and a dust core disposed between the permanent magnets adjacent to each other in the circumferential direction of the disk surface, and the permanent magnet The powder magnetic core has a tapered part to the magnetic core as a contact surface to the powder magnetic core, the powder magnetic core has a tapered part to the magnetic core as a contact surface to the adjacent permanent magnet, and the permanent magnet has the tapered part to the magnetic core as a contact surface to the adjacent permanent magnet. The powder magnetic core is a rotor that is arranged in an attitude toward the disk body, and the powder magnetic core is arranged in an attitude that the anti-magnet taper portion faces the anti-magnetic taper portion.

According to the rotor of the first invention, the basic structure is a disc body, and the permanent magnets can be mechanically fixed to the disc body using a support. Then, the contact between the powder core and the permanent magnets adjacent to each other in the circumferential direction of the disk surface is made into a contact surface with a tapered structure, and one powder magnetic core sandwiched between two adjacent permanent magnets is connected to the disk body. It can be mechanically fixed towards the Therefore, it is possible to fix the permanent magnet and the powder magnetic core without using adhesive alone.

Since permanent magnets are firmly fixed by a support, they are relatively strong, even if the rotor is enlarged and used in a high-rotation, high-temperature environment such as a main motor for a railway vehicle. This enables designs that can withstand magnetic force, centrifugal force, and high temperatures.

In addition, powder magnetic cores can be easily molded into various shapes and have excellent magnetic properties that enable low iron loss at high frequencies. - It is known to be used as the magnetic core of high-output motors. Powder magnetic cores are press-molded magnetic particles covered with an insulating coating, so they are brittle against tensile stress and cannot be locally mechanically bonded (for example, by providing a fixing piece with a bolt insertion hole and tightening the bolts). (e.g.), it is easy to break due to stress concentration. However, in the rotor of the first invention, the powder magnetic core is fixed under pressure by the contact surface (the surface of the tapered part) with the permanent magnet, so that stress concentration related to fixation is suppressed. Therefore, similarly to the fixing of permanent magnets, it is possible to design the fixing of the powder magnetic core so that it can withstand use under high rotation and high temperature environments.

In addition, when considering the method of assembling the rotor, the material that will become the permanent magnet and the powder magnetic core are connected and fixed in advance to form the shape of the rotor, and then the material that will become the permanent magnet is magnetized and rotated. Although it is possible to consider an assembly method in which the child is completed, this method requires a complicated magnetizing device and increases the difficulty of the work. On the other hand, in the rotor of the first aspect of the invention, the permanent magnets that have been magnetized in advance can be individually fixed to the disc body using a support, so there is no need to go through such a difficult process related to magnetization. Moreover, it has a structure in which one powder magnetic core is pressed and fixed to a disk body by sandwiching it between two permanent magnets. For this reason, for example, after fixing a permanent magnet first, the powder magnetic core sandwiched between the permanent magnets can be combined by aligning the tapered structures. The assembly process of assembling becomes possible. Manufacturing is much simpler than an assembly method in which magnetization is performed after assembly.

A second aspect of the present invention provides an inner diameter side support that fixes the permanent magnet by being fixed to the disc body in a state in which the support is in contact with the permanent magnet on the inner diameter side of the disc body; an outer diameter side support that fixes the permanent magnet by being fixed to the disc body while in contact with the permanent magnet on the outer diameter side of the body, and the inner diameter side support is in contact with the permanent magnet. The outer diameter side support has an outer diameter side magnet slope part as a contact surface to the permanent magnet, and the outer diameter side support has an outer diameter side magnet slope part as a contact surface to the permanent magnet. has an inner diameter side supporting device inclined portion as a contact surface to the inner diameter side support that comes into contact, and an outer diameter side supporting device inclined portion as a contact surface to the outer diameter side support that comes into contact, The inner diameter side support is fixed to the disk body in such a manner that the inner diameter side magnet inclined part is directed toward the disk body, and the outer diameter side support is fixed to the disk body in such a manner that the outer diameter side magnet inclined part is directed toward the disk body. The permanent magnet is fixed to the disc body with the inner diameter side supporting device inclined portion facing the inner diameter side opposing magnet inclined portion, and the outer diameter side supporting device inclined portion facing the outer diameter side. This is a rotor according to a first aspect of the invention, which is disposed in a position facing the anti-magnet inclined portion.

In the rotor of the second aspect of the invention, the permanent magnets are also fixed so as to be pressed against the disk body through surface contact with the support by the inclined surfaces. For this reason, it is possible to suppress the stress concentration seen in local mechanical bonding and fix it. Therefore, for example, even if the rotor is enlarged and used in a high-speed, high-temperature environment such as a main motor for a railway vehicle, it becomes possible to design the rotor to be more durable.

A third aspect of the present invention is that the inner diameter side support fixes the powder magnetic core by being fixed to the disk body in a state in which it is in contact with the powder magnetic core on the inner diameter side of the disk body, and The side support fixes the powder magnetic core by being fixed to the disk in a state in which it is in contact with the powder magnetic core on the outer diameter side of the disk; The outer diameter side support has an inner diameter side inclined part toward the magnetic core as a contact surface to the powder magnetic core, and the outer diameter side support has an outer diameter side inclined part towards the magnetic core as a contact surface to the powder magnetic core that comes into contact with the powder magnetic core. The powder magnetic core has an inner diameter side supporting device inclined portion as a contact surface to the inner diameter side support device that comes into contact with the powder magnetic core, and an outer diameter side supporting device inclined portion as a contact surface to the outer diameter side support device that comes into contact with the inner diameter side support device. , the inner diameter side support is fixed to the disk body in a posture with the inner diameter side magnetic core inclined portion facing the disk body, and the outer diameter side support tool is fixed to the disk body with the inner diameter side magnetic core inclined portion facing the disk body. The powder magnetic core is fixed to the disk body in a posture facing the body, and the powder magnetic core is arranged such that the inner diameter side-to-support slope part of the powder magnetic core faces the inner diameter side to the magnetic core slope part, and the outer diameter of the powder magnetic core is The rotor according to the first or second aspect of the present invention is arranged in such a manner that the side supporting device inclined portion faces the outer diameter side magnetic core inclined portion.

In the rotor of the third aspect of the invention, the inner diameter side and the outer diameter side of the powder magnetic core can also be firmly fixed by surface contact with the inclined surface of the support.

A fourth aspect of the present invention is that the permanent magnet includes an inner diameter magnet disposed on the inner diameter side in the circumferential direction of the disc surface, and an outer diameter magnet disposed on the outer diameter side in the circumferential direction of the disc surface, and The inner diameter magnet and the outer diameter magnet are arranged at intervals, and the inner diameter magnet and the outer diameter magnet are arranged between the adjacent inner diameter magnet and the outer diameter magnet, so that the inner diameter magnet and the outer diameter magnet can be connected to the disk. The rotor according to any one of the first to third inventions, further comprising an intermediate support that is fixed to the body.

In the rotor of the fourth aspect of the invention, the permanent magnets have a two-piece structure, and the number of fixing points can be increased at radially intermediate positions, so that the permanent magnets can be fixed even more firmly.

In a fifth aspect of the present invention, the powder magnetic core includes a one-side magnetic core that abuts on one side of the permanent magnets adjacent in the circumferential direction of the disk surface, and a second-side magnetic core that abuts on the other side, and the powder magnetic core includes the same permanent magnets. A rotor according to any one of the first to fourth inventions, which is arranged to be sandwiched between a magnetic core on one side and a magnetic core on the other side.

Further, a sixth invention is the rotation of the fifth invention, wherein the one-side magnetic core, the other-side magnetic core, and the permanent magnet sandwiched between the one-side magnetic core and the other-side magnetic core constitute an integrated unit. It is a child.

In the stator of the fifth or sixth aspect of the invention, the powder magnetic core has a two-piece configuration of one side magnetic core and the other side magnetic core divided in the circumferential direction of the disk surface. If the permanent magnet is assembled in advance by gluing the magnetic core on one side and the magnetic core on the other side in the circumferential direction of the disk surface, it is possible to fix the powder magnetic core in the process of fixing the permanent magnet to the disk body. becomes. Therefore, manufacturing of the rotor becomes easy.

A seventh invention is an axial gap type transverse flux type rotating electric machine comprising the rotor according to any one of the first to sixth inventions.

According to the seventh invention, it is possible to realize an axial gap type transverse flux type rotating electric machine having the same effects as any of the first to sixth inventions.

An eighth invention is the method for assembling a rotor according to any one of the first to fourth inventions, wherein a non-magnetic dummy magnet serving as a substitute for the permanent magnet and a powder magnetic core are provided in the disk body. , a first step of assembling the support, a second step of adhering and fixing the powder magnetic core to the disc body, and a third step of recombining the dummy magnet with the permanent magnet after the second step. It is an assembly method that includes a process and

When creating a rotating electric machine with high output and high efficiency, permanent magnets with strong magnetic force are required, and the attraction and repulsion between the permanent magnets becomes large. When assembling a rotor, a large number of permanent magnets are attached, but these strong attractive forces and repulsive forces become a hindrance from the perspective of assembly work. In addition, in order to achieve proper assembly, dimensional tolerances are controlled so that appropriate gaps are created between the permanent magnets and powder cores, which are filled with adhesive, etc., and the gaps are evenly distributed in each part. It is desirable to However, if the assembly is left to the strong attractive force of the permanent magnets, the gaps may not be uniform and unevenness may occur, resulting in an unfavorable rotor structure.

However, according to the eighth invention, after temporarily assembling the non-magnetic dummy magnet, the powder magnetic core, and the support, and once realizing an appropriate positional relationship between the permanent magnet and the powder magnetic core, By fixing the magnetic core to the disk body and then replacing the dummy magnets one by one with permanent magnets, it is possible to assemble a rotor in which the permanent magnets and the powder magnetic core have an appropriate positional relationship.

FIG. 2 is a diagram for explaining a configuration example and usage example of an axial gap type transverse flux type rotating electric machine. FIG. 3 is a side view showing a configuration example of a drive unit. The perspective view which shows the example of a structure of a rotor. An enlarged view of a part of the rotor viewed from the axial direction of the axle. FIG. 5 is a sectional view taken along line V-V in FIG. 4. FIG. 5 is a sectional view taken along VI-VI in FIG. 4. VII-VII sectional view of FIG. 4. VIII-VIII sectional view of FIG. 4. FIG. 3 is a diagram for explaining the first step of the rotor assembly method. FIG. 7 is a diagram for explaining a second step in the rotor assembly method. FIG. 3 is a diagram (part 1) for explaining the third step in the rotor assembly method. FIG. 2 is a diagram (part 2) for explaining the third step in the rotor assembly method. FIG. 7 is a diagram for explaining the rotor assembly method and shows the state after the third step. The figure which shows the example of a structure of an assembly unit. FIG. 3 is a diagram for explaining a rotor assembly method using an assembly unit. FIG. 7 is a diagram for explaining a modification of the rotor-axle coupling structure. FIG. 7 is a diagram (part 1) for explaining a modification of the connecting base. FIG. 7 is a diagram (part 2) for explaining a modification of the connecting base.

Embodiments of the present invention will be described below, but it goes without saying that the forms to which the present invention can be applied are not limited to the following embodiments.

FIG. 1 is a diagram for explaining a configuration example and an example of use of an axial gap type transverse flux type rotating electrical machine (hereinafter referred to as "ATF rotating electrical machine" for short) according to the present embodiment. Note that in order to facilitate understanding of the configuration, the ATF rotating electric machine is partially cut out to clarify the internal structure.

The ATF rotating electrical machine 100 is a so-called "direct drive main motor" whose rotating shaft (output shaft) is directly connected to the axle 3j of the wheel set 3 for a railway vehicle.
Specifically, in the ATF rotating electric machine 100, a motor case 101 is connected to a cross beam part of a bogie frame 5 for a railway vehicle via a reaction force receiving part 4. A motor control device (not shown) fixed to the body of the railway vehicle and the ATF rotating electric machine 100 are connected by a three-phase AC line 7, a sensor signal line 8, and a ground line 9. Drive current is supplied from the motor control device to the ATF rotating electric machine 100 through the three-phase AC line 7, and a detection signal from the rotation sensor 10 is input to the motor control device through the sensor signal line 8. The grounding wire 9 is brought into sliding contact with the axle 3j by a grounding device 12 provided on the ATF rotating electric machine 100, and achieves electrical grounding with the rail via the wheel axle 3. Further, a power line that supplies overhead line power (or power supplied via a power converter or the like configured according to the main circuit configuration) is connected to the motor control device.

In the wheel axle 3, a motor case 101 is supported by a bearing 102 on the axle 3j. In the main internal space of the motor case 101, rotors of three drive units 110 (110a, 110b, 110c) are fixed to the axle 3j.

FIG. 2 is a side view showing a configuration example of the drive unit 110 (110a, 110b, 110c). One drive unit 110 is installed in the motor case 101 at a position between two rotors 120 (120a, 120b) fixed to the axle 3j via the rotor fixing member 112 and these two rotors 120. and a fixed stator 170.

The rotor fixing member 112 includes a circular tube portion 113 that fits around the outer periphery of the axle 3j, and a flange portion 114 provided at an axial end of the circular tube portion 113. The circular tube portion 113 is press-fitted into the axle 3j and fixed. The flange portion 114 is fixed to the rotor 120 with bolts.

FIG. 3 is a perspective view showing a configuration example of the rotor 120.
FIG. 4 is an enlarged view of a part of the rotor 120 viewed from the axial direction of the axle 3j (same as the rotating shaft direction of the ATF rotating electric machine 100).
5 to 8 are partial cross-sectional views taken along the disk surface direction of the rotor 120, and are a VV cross-sectional view, a VI-VI cross-sectional view, a VII-VII cross-sectional view, and an VIII-VIII cross-sectional view in FIG. 4, respectively. FIG. In FIGS. 5 to 8, (1) in each figure shows the sectional view in the assembled state, and (2) in each figure shows the sectional view in the disassembled state.

As shown in FIG. 3, the rotor 120 has a hollow disk shape (flat annular shape) when viewed from the axial direction AX of the axle 3j. The rotor 120 includes a disk body 121, a connecting base 160, permanent magnets 130 (130a, 130b), a powder magnetic core 140, and a structure for fixing the permanent magnet 130 and the powder magnetic core 140 to the disk body 121. It has a support 150.

The disk body 121 is one of the basic structures of the rotor 120, and the direction perpendicular to the circular disk surface (thickness direction) is made of a thin non-magnetic material (for example, FRP (Fiber Reinforced Plastics). It is a hollow disc body made by ). The diameter of the hollow portion is set such that the axle 3j can be inserted therethrough. The disc body 121 has a plurality of through holes 123 in the edge 122 of the hollow part, and forms a mounting part for bolting to the flange part 114 (see FIG. 2) of the rotor fixing member 112.

The connection base 160 is another element forming the basic structure of the rotor 120, and is made of a non-magnetic stainless steel plate or a thin non-magnetic stainless steel plate in the direction perpendicular to the disk surface (thickness direction), which has the same shape as the disk body 121. It is an aluminum plate. Furthermore, a hole 164 (see FIG. 5) corresponding to the through hole 123 of the disk body 121 is provided at the edge of the hollow portion of the connection base 160.

Note that it is preferable that the disk body 121 and the connection base 160 be provided with holes into which positioning pins are fitted, as appropriate, to ensure a high degree of relative positional relationship during assembly.

The permanent magnets 130 include a first type permanent magnet 130a and a second type permanent magnet 130b, which have different magnetization directions. Specifically, the first type permanent magnet 130a is magnetized in a clockwise direction when viewed from the direction of the board (when viewed diagonally from the upper right in FIG. 3) with the permanent magnet 130 in front. , the second type permanent magnet 130b is magnetized in a counterclockwise direction when viewed from the direction of the board. The first type permanent magnets 130a and the second type permanent magnets 130b are alternately arranged and fixed on the same disk surface of the disk body 121 at intervals in the circumferential direction of the disk surface.

As shown in FIG. 4, one permanent magnet 130 is composed of two pieces: an inner magnet 131 and an outer magnet 132. The inner diameter magnet 131 and the outer diameter magnet 132 constituting one permanent magnet 130 are arranged and fixed in a straight line next to each other with a predetermined interval apart along the radial direction of the rotor 120.

As shown in FIG. 5, the inner diameter side magnet 131 has an inner diameter side supporting device inclined portion 133 on the inner diameter side, which is an inclined surface whose normal line faces outward with respect to the disk surface when it is fixed to the disk body 121. On the outer diameter side surface thereof, there is provided an intermediate support inclined portion 134 which is an inclined surface whose normal line is directed outward with respect to the disk surface when it is fixed to the disk body 121.

The outer diameter side magnet 132 has, on the inner diameter side, an intermediate support inclined portion 134, which is an inclined surface whose normal line faces outward with respect to the disk surface when it is fixed to the disk body 121, and on the outer diameter side, It has an outer diameter side supporting device inclined portion 135 which is an inclined surface whose normal line is directed outward with respect to the disk surface when it is fixed to the disk body 121.

In addition, as shown in FIG. 7, the outer diameter side magnet 132 has a core-to-core taper portion 136 on both sides in the circumferential direction of the disk surface, which is an inclined surface whose normal line is directed toward the disk surface when it is fixed to the disk body 121. have Although not shown, the inner diameter side magnet 131 also has core-to-core taper portions 136 on both side surfaces in the circumferential direction of the disk surface, which are inclined surfaces whose normal lines face the disk surface when fixed to the disk body 121. have That is, when the rotor 120 is assembled, both the outer diameter side magnets 132 and the outer diameter side magnets 132 are arranged with the core-to-core taper portions 136 facing the disk body 121.

Returning to FIGS. 3 and 4, the powder magnetic core 140 is arranged between the permanent magnets 130 adjacent to each other in the circumferential direction of the disk surface of the disk body 121.

As shown in FIG. 8, the powder magnetic core 140 has an inclined surface on the inner diameter side where the normal line faces outward with respect to the disk surface when the powder core 140 is fixed to the disk body 121. 142, and has an outer diameter side supporting device inclined portion 143 on the outer diameter side surface, which is an inclined surface whose normal line is directed outward with respect to the disk surface when it is fixed to the disk body 121.

Further, as shown in FIG. 7, the powder magnetic core 140 has an anti-magnet tapered portion whose side surface in the circumferential direction of the disk surface is an inclined surface whose normal line faces outward with respect to the disk surface when it is fixed to the disk body 121. 144 is formed. The magnet-to-magnet taper portion 144 corresponds to the core-to-core taper portion 136 of the permanent magnet 130, and is set at the same inclination angle with respect to the disk surface of the disk body 121 so that they are in surface contact with each other. When the rotor 120 is assembled, the powder magnetic core 140 is arranged in such a manner that the anti-magnet tapered portion 144 faces the anti-magnetic tapered portion 136.

Returning to FIGS. 3 and 4, the support 150 is a member that fixes the permanent magnet 130 and the powder magnetic core 140 to the disk body 121. Specifically, the support 150 includes an inner support 151, an intermediate support 152, and an outer support 153. As shown in FIG. 5, the inner support 151, the intermediate support 152, and the outer support 153 are fixed to the connection base 160 with mounting bolts 159. Specifically, the mounting bolt 159 is inserted into the insertion hole 124 of the disk body 121, screwed into the female threaded portion 162 of the connection base 160, and is connected to the inner support 151, the intermediate support 152, and the outer support. Each of the tools 153 is fixed to the connecting base 160 so that the disk body 121 is sandwiched therebetween.

The inner diameter side support 151 is fixed to the disk body 121 in a state in which it is in contact with the permanent magnet 130 (inner diameter side magnet 131) on the inner diameter side of the disk body 121, and fixes the abutting permanent magnet 130 to the disk body 121.

Specifically, as shown in FIG. 5, the inner diameter support 151 has a contact surface that comes into contact with the permanent magnet 130 (inner diameter magnet 131) on the side surface that becomes the outer diameter side when fixed to the disc body 121. It has an inner radially opposite magnet inclined portion 154 as an inner diameter side. The inner support 151 is fixed to the disc body 121 with the inner diameter side anti-magnet inclined portion 154 facing the disc body 121. Then, when fixed, the inner diameter side opposite magnet inclined part 154 opposes the inner diameter side opposite supporter inclined part 133 of the permanent magnet 130 and presses it toward the disc body 121.

Moreover, when paying attention to the length of the inner diameter side magnet inclined part 154 along the circumferential direction of the board surface, as shown in FIGS. It extends beyond the length corresponding to the sloped portion 133 and reaches a position opposite to the support sloped portion 142 on the inner diameter side of the powder magnetic core 140 . Therefore, the radially inner magnet inclined portion 154 also functions as the inner radially inclined portion toward the magnetic core.

Therefore, the inner-diameter-side magnet inclined portion 154 corresponds to the inner-diameter-side supporter inclined portion 133 of the inner-diameter magnet 131 and the inner-diameter supporter inclined portion 142 of the powder magnetic core 140, and is in a plane with each other. The angle of inclination is set to be the same with respect to the disk surface of the disk body 121 so that they are in contact with each other.

As shown in FIG. 4, the intermediate support 152 is disposed between the inner diameter side magnet 131 and the outer diameter side magnet 132 that are adjacent to each other in the radial direction of the rotor 120. This is a member fixed to the disc body 121.

Specifically, as shown in FIG. 5, the intermediate support 152 has an inner diameter magnet 131 and an outer diameter magnet 132 on both sides, which are the inner diameter side and the outer diameter side, respectively, when fixed to the disc body 121. It has an anti-magnet inclined portion 156 as a contact surface that comes into contact with the magnet. The anti-magnet inclined portion 156 corresponds to the intermediate support inclined portion 134, and is set at the same inclination angle with respect to the disk surface of the disk body 121 so that they are in surface contact with each other.

Further, as shown in FIG. 6, the intermediate support 152 has a magnetic core inclined portion 157 on the side surface in the circumferential direction of the disk surface as a contact surface that comes into contact with the powder magnetic core 140 when it is fixed to the disk body 121. The anti-magnetic core inclined portion 157 corresponds to the anti-magnet tapered portion 144, and is set at the same inclination angle with respect to the disk surface of the disk body 121 so that they are in surface contact with each other.

As shown in FIG. 4, the outer diameter side support 153 is fixed to the disk body 121 in a state in which it is in contact with the permanent magnet 130 (outer diameter side magnet 132) on the outer diameter side of the disk body 121. A magnet 130 is fixed to the disc body 121.

Specifically, as shown in FIG. 5, the outer diameter side support 153 has a contact surface that comes into contact with the permanent magnet 130 (outer diameter side magnet 132) on the inner diameter side side when it is fixed to the disc body 121. It has an outer diameter side magnet inclined portion 158 as a surface. The outer diameter side support member 153 is fixed to the disk body 121 with the outer diameter side anti-magnet inclined portion 158 facing the disk body 121. When fixed, the outer-diameter-side magnet inclined portion 158 faces the outer-diameter-side supporter inclined portion 135 of the permanent magnet 130 and presses it toward the disc body 121.

Further, when paying attention to the length of the outer diameter side supporting member 153 along the circumferential direction of the board surface, as shown in FIGS. It extends beyond the length corresponding to the tool inclined portion 135 and reaches a position opposite to the support tool inclined portion 143 on the outer diameter side of the powder magnetic core 140 . Therefore, the outer diameter side magnet slope portion 158 is the outer diameter side support slope portion 135 of the outer diameter side magnet 132 (see FIG. 5) and the outer diameter side support slope portion 143 of the powder magnetic core 140 (see FIG. 8). (see), and are set at the same inclination angle with respect to the disk surface of the disk body 121 so as to be in surface contact with them. Therefore, the outer diameter side magnet inclined part 158 also functions as an outer diameter side inclined part towards the magnetic core.

Next, a method for assembling the rotor 120 will be described with reference to FIGS. 9 to 13.
As shown in FIG. 9, in the first step of the rotor 120, an operator fixes the connecting base 160 to one surface of the disk body 121 by adhesive, screwing, or the like. Then, a non-magnetic dummy magnet 130D, which is a substitute for the permanent magnet 130, a powder magnetic core 140, an inner support 151, and an intermediate support 152 are assembled to the disk body 121. It is preferable that the dummy inner diameter side magnet 131D and the dummy outer diameter side magnet 132D constituting the dummy magnet 130D and the intermediate support 152 are bonded together in advance to facilitate assembly.

If it is assembled without using the dummy magnet 130D, it will be affected by the attractive force and repulsive force caused by the magnetic force, and the places where the attractive force acts will be closer than the specified position according to the design, and the predetermined gap will be removed. It is assembled with a gap relationship that is smaller than the relationship. The opposite is true where a repulsive force acts. Therefore, there is a possibility that the gap relationship that should be originally distributed becomes biased, resulting in an unfavorable state for the rotor 120, for example.

However, since the dummy magnet 130D is non-magnetic, the worker can easily align the permanent magnet 130, powder magnetic core 140, and support 150 according to the design without being affected by magnetic attraction or repulsion. It can be easily assembled to have a predetermined gap relationship at a predetermined position. Unbalanced gaps are less likely to occur, and the assembly can be performed at a more appropriate position than when no dummy is used.

In the second step performed after the first step, the worker pulls out the powder magnetic cores 140 one by one and applies adhesive to the surface of the extracted powder magnetic core 140 that contacts the disc body 121, as shown in FIG. After applying the powder, a powder magnetic core 140 is inserted into the removed place and fixed by adhesive. After all powder magnetic cores 140 are bonded, the process moves to the third step.

In the third step, as shown in FIG. 11, for one dummy magnet 130D, the intermediate support 152 is removed and the dummy magnet 130D (dummy inner diameter side magnet 131D and dummy outer diameter side magnet 132D) is removed. The permanent magnet 130 (the inner magnet 131 and the outer magnet 132) is reassembled, and the intermediate support 152 and the outer support 153 are attached. All the dummy magnets 130D are replaced with permanent magnets 130 one by one. It is preferable to bond the inner diameter side magnet 131 and the outer diameter side magnet 132 constituting the permanent magnet 130 and the intermediate support member 152 together in advance to improve workability.

When all the dummy magnets 130D have been reassembled, assembly of the rotor 120 is completed, as shown in FIG. 13. When the assembly is completed, the permanent magnet 130 is attached to a disc body by the inner diameter side support 151, the intermediate support 152, and the outer diameter side support 153 at the inner diameter side end, the outer diameter side end, and an intermediate position between these. 121 and mechanically fixed. Further, when the assembly is completed, the powder magnetic core 140 has its inner diameter side end and outer diameter side end pressed toward the disc body 121 by the inner diameter side supporter 151 and the outer diameter side supporter 153, respectively. Mechanically fixed. In addition, if we pay attention to the circumferential direction of the disk surface, the powder magnetic core 140 is supported by the disk body 121 by the two adjacent permanent magnets 130 (specifically, the inner diameter side magnet 131 and the outer diameter side magnet 132) and the intermediate support 152. It is pressed down and mechanically fixed.

The assembled rotor 120 undergoes rotational balance adjustment as appropriate. At this time, the connecting base 160 may be used as a mounting structure for a balance weight to appropriately correct the center of gravity position. Alternatively, if the connection base 160 is set to have a sufficient thickness, the correction may be made by cutting the connection base 160.

Note that the stator 170 (see FIG. 2) can be realized in the same manner as a known axial gap type transverse flux motor. For example, the stator disclosed in Patent Document 3 can be used.

As described above, according to the present embodiment, it is possible to provide a new technique for fixing a permanent magnet and a magnetic core related to a rotor of an axial gap type transverse flux type rotating electrical machine (ATF rotating electrical machine).

In the ATF rotating electrical machine 100, a disk body 121 is used as the basic structure of the rotor 120, and a permanent magnet 130 is mechanically fixed to this with a support 150. Then, the contact between the permanent magnets 130 and the powder magnetic core 140 that are adjacent to each other in the circumferential direction of the disk surface is a surface contact with a tapered structure, and one powder magnetic core 140 sandwiched between two adjacent permanent magnets 130 is connected to the disk. 121 and can be mechanically fixed. Therefore, it is possible to fix the permanent magnet and the powder magnetic core without using adhesive alone.

Since the permanent magnet 130 is firmly fixed by the support 150, even if the rotor is enlarged and used in a high-rotation, high-temperature environment such as a main motor for a railway vehicle, it is relatively small. This enables designs that can withstand strong centrifugal force.

Moreover, since the powder magnetic core 140 is originally press-molded from magnetic particles coated with an insulating film, it exhibits brittleness against tensile stress and is likely to be damaged due to stress concentration if local mechanical bonding is performed. However, in the ATF rotary electric machine 100, the powder magnetic core 140 is fixed by pressing against the surface of the permanent magnet 130, so that stress concentration related to fixing is suppressed. Therefore, similarly to the fixing of the permanent magnet 130, the fixing of the powder magnetic core 140 can be designed to withstand even if used in a high rotation and high temperature environment.

In addition, in the assembly process of the rotor 120, the ATF rotating electric machine 100 is temporarily assembled using the non-magnetic dummy magnet 130D, after achieving an appropriate positional relationship between the permanent magnet 130 and the powder magnetic core 140. By replacing the dummy magnets 130D one by one with permanent magnets, it is possible to assemble the permanent magnets 130 and the powder magnetic core 140 in an appropriate positional relationship.

[Modified example]
Although an example of an embodiment to which the present invention is applied has been described above, the embodiment to which the present invention is applicable is not limited to the above embodiment, and components may be omitted, added, or changed as appropriate. can.

(Modification 1)
In the above embodiment, an example was shown in which the ATF rotating electric machine 100 was used as a "direct drive type main motor" for a railway vehicle, but the use of the ATF rotating electric machine 100 is not limited to this. For example, it can be used as a prime mover for transportation vehicles, a prime mover for industrial machinery such as pumps, and a generator. Even when the ATF rotating electric machine 100 is used as a main electric motor for a railway vehicle, it also functions as a regenerative brake, and at that time becomes a generator.

(Modification 2)
Further, in the above embodiment, one ATF rotating electrical machine 100 has been illustrated as having three drive units 110, but if the number of drive units 110 is an integral multiple of "3", for example, one ATF rotating electrical machine 100 has three drive units 110. The number of drive units 110 provided can be set as appropriate.

(Modification 3)
Further, it is also possible to configure the powder magnetic core 140 of the above embodiment to be divided in the circumferential direction of the disk surface, so that a plurality of magnetic core parts constitute one powder magnetic core 140.
Specifically, as shown in FIG. 14, the powder magnetic core 140 is divided into one side magnetic core 140L that abuts one side of the permanent magnets 130 adjacent in the circumferential direction of the disk surface, and the other side magnetic core 140R that abuts the other side. It has a two-piece structure. In FIG. 14, the broken line indicates the size of the powder magnetic core 140 in the above embodiment. Then, in advance, one side magnetic core 140L is attached to one side of the same permanent magnet 130 in the circumferential direction of the disk surface, and the other side magnetic core 140R is attached to the other side of the disk surface circumferential direction, so that the one side magnetic core 140L and the other side magnetic core 140R are connected. An assembly unit 180 sandwiching one permanent magnet 130 is created in advance.

Of course, the dummy magnetic core 140D in the above embodiment has a two-piece configuration in the same manner, and a dummy assembly unit 180D is created together with the dummy magnet 130D.

As shown in FIG. 15, in the assembly process of the rotor 120B when this configuration is adopted, the first process is to assemble the dummy assembly unit 180D, and the second process is to assemble the dummy assembly unit 180D. The assembly units 180 are replaced one by one. That is, by creating the assembly unit 180, the second process and the third process of the above embodiment can be combined into one process.

(Modification example 4)
Further, the relationship between the support 150 and the members supported by it is not limited to the above embodiment. For example, as shown in FIG. 15, (1) n pieces (n is an integer of 2 or more; n=3 in FIG. 15) of the inner diameter side supports 151 in the above embodiment are combined into one integrated inner diameter side support 151E. (2) The m outer diameter side supports 153 in the above embodiment (m is an integer of 2 or more; in the example of m=3 in FIG. 15) are made into one integrated outer diameter side support 153E, Either or both configurations are also possible.

(Modification example 5)
The contents of the first step and the second step are not limited to those in the above embodiment.
For example, markings are made on the surface of the disk body 121 to indicate the mounting position of the powder core 140 (or a recess is created into which the surface of the powder core 140 is shallowly fitted). Then, in the first step, the powder cores 140 coated with adhesive on the board side are pasted on the marked mounting positions, and before the adhesive dries, the dummy magnet 130, inner support 151, and intermediate support are attached. The fixtures 152 may be assembled with the appropriate designed gap relationship. That is, the first step may also be configured to serve as the second step of fixing the powder core 140 to the disc body 121.

Alternatively, grooves are separately provided in advance on the plate side of the powder magnetic core 140. In addition, an adhesive injection path is provided in the disk body 121 and the connection base 160 to reach the groove of the powder magnetic core 140 when the powder magnetic core 140 is attached to the disk surface of the disk body 121. Then, the second step may be a step of injecting adhesive into this injection path to fix the powder magnetic core 140 to the disc body 121.

(Modification 6)
Further, in the embodiment described above, the rotor 120 and the axle 3j are connected by fixing the connection base 160, the disk body 121, and the flange 114 by sandwiching and tightening them with bolts and nuts, but the present invention is not limited to this. For example, FIG. 16 is a partial cross-sectional view in the radial direction showing a modified example of the rotor fixing member 112B. It may be fixed by being sandwiched between the flange portion 114 and the connection base 160 like the rotor fixing member 112B. Specifically, the fixing bolt 116 is inserted into the hole 164 of the connection base 160 and the through hole 123 of the disc body 121, and is screwed into the female screw portion 115 of the flange portion 114 and tightened. Since the flange portion 114 has an annular shape when viewed from the axial direction of the axle 3j, the tightening axial load of the fixing bolt 116 is widely distributed between the flange portion 114 and the edge 122 of the disk body 121, and is distributed around the through hole 123. The stress of the tightening axial load can be dispersed.

(Modification example 7)
Further, in the above embodiment, the shape of the connecting base 160 is a thin plate having a circular ring having substantially the same shape as the disk body 121 when viewed from the axial direction AX of the axle, but the shape is not limited to this. For example, like the connection base 160B shown in FIG. 17, when viewed from the axial direction AX of the axle, there are three ring parts 165 (165a, 165b, 165c) having female threaded parts 162 corresponding to the mounting bolts 159, and spoke parts. 166 may be used in a mesh-like shape. Furthermore, for example, like the connection base 160C in FIG. 18, it is also possible to have a configuration in which connection rods 167 radially connect the three female threaded portions 162 of one permanent magnet 130 in the radial direction. By adopting these shapes, it is possible to reduce the weight of the rotor 120 and reduce loss due to generation of eddy currents while maintaining the coupling strength of the rotor 120.

100...ATF rotating electric machine 110...Drive unit 120, 120B...Rotor 121...Disc body 130...Permanent magnet 131...Inner diameter side magnet 132...Outer diameter side magnet 133...Inner diameter side support tool inclined part 134...Intermediate support inclined part 135... Outer diameter side supporting tool inclined part 136... Core tapered part 140... Powder magnetic core 140L... One side magnetic core 140R... Other side magnetic core 142... Inner diameter side supporting tool inclined part 143... Outer diameter side supporting tool inclined part 144... Magnet taper part 150... Support tool 151... Inner diameter side support tool 152... Intermediate support tool 153... Outer diameter side support tool 154... Inner diameter side magnet inclined part 156... Magnet inclined part 157... Magnetic core inclined part 158... Outer diameter side magnet inclined portion 160...Connection base 180...Assembly unit

Claims (8)

A rotor of an axial gap type transverse flux type rotating electrical machine,
A disk body,
Permanent magnets arranged at intervals in the circumferential direction of the disc surface of the disc body;
a support for fixing the permanent magnet to the disc body;
a powder magnetic core disposed between the permanent magnets adjacent in the circumferential direction of the disk surface;
Equipped with
The permanent magnet has a core-to-core taper portion as a contact surface to the adjacent powder magnetic core,
The powder magnetic core has an anti-magnet tapered portion as a contact surface to the adjacent permanent magnet,
The permanent magnet is arranged with the tapered portion facing the magnetic core facing the disk body,
The powder magnetic core is arranged in such a manner that the anti-magnet tapered portion faces the anti-magnetic tapered portion,
rotor. The support includes an inner support that fixes the permanent magnet by being fixed to the disk while being in contact with the permanent magnet on the inner diameter side of the disk, and an inner support that fixes the permanent magnet by contacting the permanent magnet on the inner diameter side of the disk. an outer diameter side support that fixes the permanent magnet by being fixed to the disc body while in contact with the permanent magnet;
The inner diameter side support has an inner diameter side facing magnet slope portion as a contact surface to the permanent magnet that comes into contact with it,
The outer-diameter side support has an outer-diameter side-to-magnet slope portion as a contact surface to the permanent magnet that comes into contact with it,
The permanent magnet has an inner-diameter side-to-support slope part as a contact surface to the inner-diameter-side support to which it abuts, and an outer-diameter side-to-support slope part as a contact surface to the outer-diameter side support to which it abuts. death,
The inner diameter side support is fixed to the disc body with the inner diameter side magnet inclined portion facing the disc body,
The outer diameter side support is fixed to the disc body with the outer diameter side magnet inclined portion facing the disc body,
The permanent magnet is arranged in such a manner that the inner diameter side supporting device inclined portion faces the inner diameter side supporting device inclined portion, and the outer diameter side supporting device inclined portion faces the outer diameter side supporting device inclined portion. Ru,
A rotor according to claim 1. The inner diameter side support fixes the powder magnetic core by being fixed to the disk body while being in contact with the powder magnetic core on the inner diameter side of the disk body,
The outer diameter side support fixes the powder magnetic core by being fixed to the disk body while being in contact with the powder magnetic core on the outer diameter side of the disk body,
The inner diameter side support has an inner diameter side magnetic core inclined portion as a contact surface to the powder magnetic core that comes into contact with it,
The outer diameter side support has an outer diameter side inclined part toward the magnetic core as a contact surface to the powder magnetic core that comes into contact with it,
The powder magnetic core has an inner-diameter side-to-support slope part as a contact surface to the inner-diameter-side support to which it abuts, and an outer-diameter side-to-support slope part as a contact surface to the outer-diameter side support to which it abuts. have,
The inner diameter side support is fixed to the disc body with the inner diameter side magnetic core inclined portion facing the disc body,
The outer diameter side support is fixed to the disc body with the outer diameter side magnetic core inclined portion facing the disc body,
The powder magnetic core has an inner diameter side supporting device inclined portion of the powder magnetic core opposed to the inner diameter side supporting device inclined portion, and an outer diameter side supporting device inclined portion of the powder magnetic core is opposed to the outer diameter side supporting device inclined portion. Placed in a position facing the slope,
A rotor according to claim 2 . The permanent magnets include an inner diameter magnet arranged on the inner diameter side in the circumferential direction of the board surface, and an outer diameter side magnet arranged on the outer diameter side in the circumferential direction of the board surface,
The adjacent inner diameter side magnet and the outer diameter side magnet are arranged with an interval,
further comprising an intermediate support disposed between the adjacent inner diameter magnet and the outer diameter magnet to fix the inner diameter magnet and the outer diameter magnet to the disc body;
A rotor according to any one of claims 1 to 3. The powder magnetic core has one side magnetic core that contacts one side of the permanent magnets adjacent in the circumferential direction of the disk surface, and the other side magnetic core that contacts the other side, and the same permanent magnet is connected to the one side magnetic core and the other side magnetic core. placed between magnetic cores,
A rotor according to any one of claims 1 to 4. The one-side magnetic core, the other-side magnetic core, and the permanent magnet sandwiched between the one-side magnetic core and the other-side magnetic core constitute an integrated unit;
A rotor according to claim 5. An axial gap type transverse flux type rotating electric machine comprising the rotor according to any one of claims 1 to 6. A method for assembling a rotor according to any one of claims 1 to 4, comprising:
a first step of assembling a non-magnetic dummy magnet, the powder magnetic core, and the support tool to the disk body;
a second step of fixing the powder magnetic core to the disc body;
a third step of recombining the dummy magnet with the permanent magnet after the second step;
Assembly method including.

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