JPH09168252A - Slot insulation magnetic wedge and motor employing it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the efficiency of a motor by bonding a thin plate of crystalline magnetic alloy having composition represented by a specified structural formula and specified electric resistance and thickness on one surface of a thin nonmagnetic insulating material such that the thin nonmagnetic insulating material directs toward the coil side in a stator slot. SOLUTION: The slot insulating magnetic wedge is constituted of a magnetic material layer comprising a thin plate of 100μm or less of crystalline magnetic alloy having electric resistance of 10-200Ω.cm and exhibiting conductivity laminated on a thin nonmagnetic insulating material. On the opening 14a side in a stator slot 14 of the motor, the slot insulating wedge 13 is inserted into the stator 14 such that the thin nonmagnetic insulating material 11 directs in the direction of the coil. The thin plate of the crystalline magnetic alloy is composed of a permalloy based alloy having composition represented by a general formula Ni100-a-b Fea Mb (in the formula, M is at least one element selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Si, Ai, Co and Cu, and 15<=a<=25at%, 0<=b<=10at%).

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a slot insulating magnetic wedge inserted into a stator slot of an electric motor and an electric motor using the same.

[0002]

2. Description of the Related Art For the purpose of improving the efficiency and power factor of an electric motor or reducing electromagnetic vibration noise, it is common practice to insert a magnetic wedge into the opening side of a stator slot of the electric motor. By inserting the magnetic wedge, the magnetic imbalance between the stator slot opening of the electric motor and the stator teeth is corrected, and the magnetic flux distortion in the electric motor air gap is reduced,
Since the loss due to the harmonic magnetic flux generated from the rotor is suppressed, various characteristics of the electric motor are improved.

FIG. 5 is a partial configuration diagram showing a main part of an electric motor using a conventional general magnetic wedge. In the figure, the stator slot 1 of the electric motor is opened toward the rotor 2 (1
a), and the magnetic wedge 3 having a trapezoidal cross section is inserted on the side of the opening 1a. The magnetic wedge 3 is made of, for example, iron powder or ferrite powder hardened together with resin or the like. A coil 4 is housed in the stator slot 1, and the magnetic wedge 3 also plays a role of preventing the coil 4 from protruding.

By the way, the characteristics of the electric motor are generally improved in proportion to the amount of the coil 4 housed in the slot 1. Therefore, in the trapezoidal magnetic wedge 3 shown in FIG. 5, the effective sectional area of the slot 1 is impaired,
As a result, there is a drawback that the effect of inserting the magnetic wedge 3 cannot be sufficiently obtained. In addition, the magnetic wedge produced by solidifying magnetic powder with resin or the like has a mechanical strength that is not so large, and thus has a problem in reliability such as chipping or cracking during insertion or during use.

Therefore, for the purpose of eliminating the above-mentioned drawbacks, as shown in FIG. 6, an insulating thin leaf material 5a used as a wedge material and a ferrite 5b which is a magnetic material are used.
It has been proposed that the magnetic wedges 5 are formed by coating and integrating them (see Japanese Utility Model Laid-Open No. 59-18548).
This is expected to bring out the effect of a magnetic wedge, make the amount of coil that can be stored in the slot equal to that of a non-magnetic thin leaf material, and enable automatic wedge insertion. It is a method.

However, in the case of a magnetic wedge in which a thin material is coated with a magnetic material such as ferrite, peeling may occur depending on the thickness of the coating layer, and like the magnetic wedge made of solidified magnetic powder, the magnetic wedge may be inserted or used. There were problems such as chipping and cracking inside. Further, sufficient effects have not been obtained for improving the efficiency of electric motors, and improvement from this point has been strongly desired.

On the other hand, a magnetic wedge using an amorphous alloy ribbon as a magnetic material is disclosed in Japanese Patent Laid-Open Nos. 58-19138 and 58-58.
No. 22554, No. 59-175350, etc., these magnetic wedges had the following problems, respectively. That is, in JP-A-58-19138,
As shown in FIG. 7, a plurality of amorphous alloy ribbons 6a
With its longitudinal direction substantially parallel to the winding in the slot,
Moreover, the magnetic wedges 6 are described so that the latitudinal direction thereof is substantially parallel to the center line direction of the core cross section. Such a magnetic wedge requires an extremely large number of steps for manufacturing, and since it is necessary to deal with the mechanical strength required as the wedge only by the lamination adhesive strength, sufficient strength cannot be obtained. Had a problem. Further, similarly to the magnetic wedge in which magnetic powder is solidified with resin or the like, there is a drawback that the amount of coils accommodated in the slot is reduced and the effect of inserting the magnetic wedge cannot be sufficiently obtained.

Further, the magnetic wedge described in Japanese Patent Laid-Open No. 58-22554 is also not sufficient because it requires an extremely large number of steps for its production and its mechanical strength is only the laminating adhesive strength. Also, there is a problem that the effect of improving efficiency cannot be sufficiently obtained because the occupied area in the slot is large. Further, there is a problem that it is necessary to continuously laminate thin strips having different widths, which is not practical in the manufacturing process.

Further, as shown in FIG. 8, the magnetic wedge disclosed in Japanese Patent Laid-Open No. 59-175350 alternates between an amorphous alloy ribbon 7a and a synthetic resin layer 7b or a synthetic resin 7b containing magnetic powder. Since the magnetic wedges are stacked on top of each other, the thickness of the magnetic wedge becomes large, and there is a problem in that high efficiency cannot be achieved sufficiently.

[0010]

As described above, since the conventional magnetic wedge has a small mechanical strength, sufficient reliability cannot be obtained, and the shape of the magnetic wedge and the characteristics of the magnetic material cannot be obtained. From this point, the efficiency of the electric motor cannot be sufficiently increased, and it has been strongly desired to improve these points.

The present invention has been made in order to solve such a problem, and an object thereof is to provide a slot insulating magnetic wedge which is space-saving, brings high efficiency of an electric motor, and is excellent in reliability. Moreover, it is an object of the present invention to provide a motor with high efficiency by using such a slot insulating magnetic wedge.

[0012]

A slot insulating magnetic wedge of the present invention is a slot inserted in a curved or bent state near the center of the opening of a stator slot of a motor so as to contact the inner surface of the stator slot. An insulating magnetic wedge, which is joined to a non-magnetic insulating thin leaf material and one surface of the non-magnetic insulating thin leaf material so that the non-magnetic insulating thin leaf material faces the coil disposed in the stator slot. And an electric resistance of 10 to 200 μΩ · cm and a thickness of 100 μm or less (not including 0), and a general formula: Ni _100-ab Fe _a M _b (where M is Ti, Zr, Hf, V, Nb, Ta, C
At least one element selected from r, Mo, W, Mn, Si, Al, Co, and Cu, and a and b are numbers satisfying 15 ≦ a ≦ 25at% and 0 ≦ b ≦ 10at%, respectively. A), a magnetic material layer composed of a crystalline magnetic alloy thin plate whose composition is substantially represented by (1).

An electric motor according to the present invention includes a rotor, a stator provided with a slot having an opening opened toward the rotor, a coil arranged in the slot of the stator, and the slot. A slot insulating magnetic wedge inserted in a curved or bent state near the center of the opening so as to contact the inner surface of the slot insulating magnetic wedge, wherein the slot insulating magnetic wedge is the slot insulating magnetic wedge of the present invention described above. It is characterized by being.

In the present invention, the electric resistance is 10 to 200 μm.
Since a crystalline magnetic alloy thin plate of Ω · cm is bonded to a non-magnetic insulating thin leaf material, a slot insulating magnetic wedge having an extremely simple and simple structure can be obtained. Further, the slot insulating magnetic wedge of the present invention has an extremely simple structure as described above, and the crystalline magnetic alloy thin plate also contributes to the improvement of strength, so that extremely high reliability is obtained. Furthermore, since the thickness of the non-magnetic insulating thin leaf material can be reduced, the wedge itself can be thinned as a result. As described above, the slot insulating magnetic wedge of the present invention improves efficiency by using a magnetic material having an electric resistance of 10 to 200 μΩ · cm, and at the same time, it can be made thin, so that an insertion space is small. Therefore, it is possible to obtain a sufficient effect as a magnetic wedge. Therefore, it is possible to extremely effectively improve the efficiency of the electric motor. Further, since the structure is simple, the manufacturing is easy, and the reliability can be improved.

[0015]

Embodiments of the present invention will be described below.

In the slot insulating magnetic wedge of the present invention, a magnetic material layer made of a crystalline magnetic alloy thin plate having an electric resistance of 10 to 200 μΩ · cm and a non-magnetic insulating thin leaf material are laminated and joined, In addition to improving the efficiency of the electric motor, the mechanical strength is increased to improve reliability. That is, even if the electric resistance of the magnetic material layer made of a crystalline magnetic alloy thin plate is less than 10 μΩcm,
Even if it exceeds Ω · cm, high efficiency cannot be obtained and the effect as a magnetic wedge is reduced. The electric resistance of the magnetic material layer made of a crystalline magnetic alloy thin plate is more preferably in the range of 20 to 180 μΩ · cm, and particularly preferably in the range of 40 to 160 μΩ · cm.

The thickness of the magnetic material layer made of such a crystalline magnetic alloy thin plate is 100 μm or less (however, 0 is not included). When the thickness of the magnetic material layer exceeds 100 μm, peeling is likely to occur and reliability decreases, and
The occupied area in the slot increases, which results in hindering higher efficiency.

In the present invention, as shown in FIG. 1, a slot insulating magnetic wedge 13 is formed by joining a non-magnetic insulating thin leaf material 11 and a crystalline magnetic alloy thin plate 12. The non-magnetic insulating thin leaf material 11 and the crystalline magnetic alloy thin plate 12 are joined by a double-sided adhesive sheet or various adhesives. The thickness of the crystalline magnetic alloy thin plate 12 is preferably in the range of 1 to 100 μm. If the layer thickness is less than 1 μm, mechanical strength that can withstand lamination cannot be obtained. The thickness of the crystalline magnetic alloy thin plate 12 is more preferably in the range of 20 to 100 μm.

As the non-magnetic insulating thin leaf material 11, a polyester film, a polyethylene terephthalate film, a polyamide or polyimide film, an aromatic aramid paper or the like which is used as an ordinary insulating wedge material can be used. The thickness of the non-magnetic insulating thin leaf material 11 varies depending on the thickness of the crystalline magnetic alloy thin plate 12, but is usually 10
It is preferably about 500 μm. This is because the crystalline magnetic alloy thin plate 12 also contributes to the improvement of strength.

In actual use, the slot insulating magnetic wedge 13 is curved as shown in FIG. 2 or the slot insulating magnetic wedge 13 is bent into a U-shaped cross section as shown in FIG. Then, as shown in FIG. 4, the stator slot 1 is provided in the stator slot 14 of the electric motor at the opening 14a side.
Insert so that it touches the inner surface of 4. At this time, the slot insulating magnetic wedge 13 is inserted into the stator slot 14 so that the non-magnetic insulating thin leaf material 11 faces the coil 15. In the figure, 16 is a U-shaped insulating material. In addition, by irradiating an energy beam such as an electron beam or a laser beam, scratches can be introduced at an arbitrary angle of the crystalline magnetic alloy thin plate to give magnetic anisotropy. Further, the magnetic anisotropy can be imparted by magnetic field heat treatment at a Curie temperature of the magnetic material or lower. Furthermore, a metal film having better electric conductivity than the magnetic material used may be formed on the surface of the magnetic material layer made of a crystalline magnetic alloy thin plate. As a result, noise can be reduced. Any method such as a plating method, a pressure bonding method, and ultrasonic bonding may be used as the means, but the plating method is particularly preferable. The metal used therefor is preferably copper, nickel and its alloys, and its thickness is 50μ depending on the ratio with the magnetic layer.
m or less.

The crystalline magnetic alloy thin plate in the present invention is a magnetic alloy having a composition substantially represented by the following formula (1):
It is made of so-called permalloy alloy.

General formula: Ni _100-ab Fe _a M _b (1) (wherein M is Ti, Zr, Hf, V, Nb, Ta, C
At least one element selected from r, Mo, W, Mn, Si, Al, Co, and Cu, and a and b are numbers satisfying 15 ≦ a ≦ 25at% and 0 ≦ b ≦ 10at%, respectively. Here, when the Fe content is 15 to 25 at%, the soft magnetic characteristics are less likely to deteriorate in the manufacturing process, and the mechanical strength is improved by the addition of the M element. The strength as a magnetic wedge also increases.

Such a crystalline magnetic alloy thin plate can be made to have a predetermined plate thickness by repeating rolling with a multi-stage roll or the like. The crystalline magnetic alloy thin plate may or may not be heat-treated after rolling, but it is preferable to use a heat-treated material.

[0024]

Next, an embodiment of the present invention will be described. The compositions shown below are all atomic%.

Example 1 First, the composition is represented by Ni ₇₉ Fe ₁₈ Nb ₃ and the plate thickness is 20 μm.
An m 2 crystalline magnetic alloy thin plate (electrical resistance: 55 μΩ · cm, saturation magnetic flux density: 8.1 kG) was prepared and heat-treated at an optimum temperature in the range of 800 to 1100 ° C. After that, the crystalline magnetic alloy thin plate and a polyester film having a thickness of 0.2 mm were adhered to each other using an epoxy elastic adhesive to produce an insulating magnetic wedge having a width of 10 mm and a length of 100 mm.

The insulating magnetic wedge obtained in this manner is
The efficiency of the motor was evaluated by inserting it into each slot of a 2.2 kW motor by bending it.

As a comparison with the present invention, the thickness is 0.25 mm.
The polyester film of No. 3 was used as a wedge and was inserted into the same portion of the motor, and the same evaluation was performed. The motor efficiency was calculated by measuring the rotation speed and torque of the electric motor using a torque meter on the output side and calculating the ratio P 1 to the electric power on the input side from the following formula.

P = 975 × T / r [T: torque (kg · m),
r: Number of revolutions (rpm)] As a result, the efficiency of the wedge according to Comparative Example 1 was 82.2%, while the efficiency was 82.2% when the magnetic wedge according to Example 1 was used.
A significant improvement in efficiency was recognized, at 0%.

Example 2 A crystalline magnetic alloy thin plate having a plate thickness of 15 μm (electric resistance: Ni _78.5 Fe _18.0 Ta _3.0 Si _0.3 Mn _0.2)
65μΩ ・ cm, saturation magnetic flux density: 7.9kG) was prepared and
The heat treatment was performed at the optimum temperature in the range of 00 to 1100 ° C. Then, the crystalline magnetic alloy thin plate and a polyethylene terephthalate (PET) film having a thickness of 0.2 mm were adhered to each other using a urethane adhesive to prepare a magnetic wedge having a width of 10 mm and a length of 100 mm. Similar to Example 1, the magnetic wedge was bent into a U-shape so as to fit in the slot portion of the motor and inserted into each slot portion, and the efficiency of the motor was evaluated.

As a comparative example with the present invention, a thickness of 0.2
A wedge having the same shape only with a PET film of mm (Comparative Example 2), a wedge obtained by kneading and curing iron powder and resin (3 wt%) (Comparative Example 3), iron powder and resin (1 wt%) Kneading and molding,
Hardened wedge (Comparative example 4), Ferrite wedge (Comparative example 5 /
Kneading with resin), Fe ₈₀ B ₂₀ wedge (Comparative example 6 / thickness 35 μm,
Laminated in parallel with the center direction of the iron core), Fe ₇₀ Co ₁₀ B ₂₀ wedge (Comparative Example 7 / thickness 33 μm, 5 laminated on 0.2 mm PET),
Ni wedge (Comparative Example 8 / thickness 20 μm, laminated with 0.2 mm PET,
Furthermore, an insulating layer of 2 μm was applied on the ribbon), and the efficiency of the motor was similarly evaluated using these. The results of these comparative examples are also shown in Table 1.

[0031]

[Table 1] Further, when the magnetic wedge according to Example 2 and each of the magnetic wedges according to Comparative Examples 6 and 7 were examined for insertability into a slot, the magnetic wedge according to Example 2 had no defects or the like, whereas Comparative Example 6 Comparative example 6 in the case of each magnetic wedge according to
In the case of Comparative Example 7, about 15% of the pieces were divided into two parts due to peeling from the bonded portion, and in Comparative Example 7, the magnetic layers laminated were turned up about 20%. From these, it is clear that the magnetic wedge of the present invention has excellent reliability.

[0032]

As described above, according to the present invention, since the magnetic material layer made of a crystalline magnetic alloy thin plate having an electric resistance of 10 to 200 μΩ · cm and the non-magnetic insulating thin leaf member are joined, It is possible to provide a slot insulating magnetic wedge that has a simple structure and is made thin, and that can sufficiently function as a magnetic wedge. Therefore, it greatly contributes to the improvement of efficiency and reliability of the electric motor. Further, according to the electric motor of the present invention, it is possible to improve efficiency and the like.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a main configuration of a slot insulating magnetic wedge according to an embodiment of the present invention.

FIG. 2 is a perspective view showing an example of the overall shape of the slot insulating magnetic wedge shown in FIG.

FIG. 3 is a perspective view showing another example of the overall shape of the slot insulating magnetic wedge shown in FIG.

FIG. 4 is a plan view showing a usage example of the slot insulating magnetic wedge according to the embodiment of the present invention and a main configuration of an electric motor according to the embodiment of the present invention.

FIG. 5 is a plan view showing a conventional magnetic wedge together with a stator slot.

FIG. 6 is a plan view showing another conventional magnetic wedge.

FIG. 7 is a perspective view showing still another conventional magnetic wedge.

FIG. 8 is a perspective view showing another conventional magnetic wedge.

[Explanation of symbols]

 11 ... Non-magnetic insulating thin sheet material 12 ... Crystalline magnetic alloy thin plate 13 ... Slot insulating magnetic wedge 14 ... Stator slot 14a ... Opening 15 ... Coil

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Shieyasu Mochizuki 1923-2-504 Sunarinorida, Kanie-cho, Kaifu-gun, Aichi Prefecture (72) Inventor Tadatomo Kimura 260-73, Hiratsune-machi, Yokkaichi-shi, Mie Inventor Ozawa Shigeo 407-6 Mamemachi, Yokkaichi-shi, Mie

Claims (2)

[Claims] 1. A slot insulating magnetic wedge which is inserted in a curved or bent state near the center of the opening of the stator slot so as to come into contact with the inner surface of the stator slot of the electric motor. , On one surface of the non-magnetic insulating thin leaf material, the non-magnetic insulating thin leaf material is bonded so as to face the coil direction disposed in the stator slot, and the electrical resistance is 10 ~ 200μΩ · cm, thickness Is 100 μm or less (not including 0), and a general formula: Ni _100-ab Fe _a M _b (where M is Ti, Zr, Hf, V, Nb, Ta, C).
At least one element selected from r, Mo, W, Mn, Si, Al, Co, and Cu, and a and b are numbers satisfying 15 ≦ a ≦ 25at% and 0 ≦ b ≦ 10at%, respectively. And a magnetic material layer made of a crystalline magnetic alloy thin plate whose composition is substantially represented by (1). 2. A rotor, a stator provided with a slot having an opening opening toward the rotor, a coil arranged in the slot of the stator, and an inner surface of the slot. As described above, in the electric motor including the slot insulating magnetic wedge inserted in a curved or bent state in the vicinity of the center of the opening, the slot insulating magnetic wedge includes a non-magnetic insulating thin leaf material and a non-magnetic insulating thin leaf material. On one surface, the non-magnetic insulating thin leaf material is bonded so as to face the coil direction, and the electrical resistance is 10 ~ 200μΩ · cm, thickness 100μm or less (however,
In addition to the general formula: Ni _100-ab Fe _a M _b (wherein M is Ti, Zr, Hf, V, Nb, Ta, C).
At least one element selected from r, Mo, W, Mn, Si, Al, Co, and Cu, and a and b are numbers satisfying 15 ≦ a ≦ 25at% and 0 ≦ b ≦ 10at%, respectively. And a magnetic material layer made of a crystalline magnetic alloy thin plate whose composition is substantially represented by (1).