WO2018025407A1 - Rotor à pôles conséquents, moteur électrique et climatiseur - Google Patents

Rotor à pôles conséquents, moteur électrique et climatiseur Download PDF

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Publication number
WO2018025407A1
WO2018025407A1 PCT/JP2016/073135 JP2016073135W WO2018025407A1 WO 2018025407 A1 WO2018025407 A1 WO 2018025407A1 JP 2016073135 W JP2016073135 W JP 2016073135W WO 2018025407 A1 WO2018025407 A1 WO 2018025407A1
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WO
WIPO (PCT)
Prior art keywords
core
pole
rotor
opening
outer peripheral
Prior art date
Application number
PCT/JP2016/073135
Other languages
English (en)
Japanese (ja)
Inventor
優人 浦邊
及川　智明
山本　峰雄
石井　博幸
洋樹 麻生
隼一郎 尾屋
諒伍 ▲高▼橋
Original Assignee
三菱電機株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 三菱電機株式会社 filed Critical 三菱電機株式会社
Priority to PCT/JP2016/073135 priority Critical patent/WO2018025407A1/fr
Priority to JP2018531715A priority patent/JP6545387B2/ja
Publication of WO2018025407A1 publication Critical patent/WO2018025407A1/fr

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2746—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets arranged with the same polarity, e.g. consequent pole type
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets

Definitions

  • the present invention relates to a continuous pole type rotor, an electric motor, and an air conditioner.
  • a rare earth magnet having a high energy density such as a neodymium sintered magnet is generally used as a permanent magnet of an electric motor mounted on a compressor of an air conditioner.
  • An electric motor using a neodymium sintered magnet has been developed for an air conditioner fan.
  • Permanent magnets are generally processed into a specified shape by cutting block-like chunks. For this reason, the processing cost increases as the number of permanent magnets used in the electric motor increases.
  • a rotor As a method for reducing the number of permanent magnets used in an electric motor, there is a method in which a rotor is constituted by a so-called continuous pole.
  • a continuous pole type rotor disclosed in Patent Document 1 magnet magnetic poles formed by permanent magnets and salient poles formed on the core material without using permanent magnets are alternately arranged in the circumferential direction. Therefore, the number of magnet magnetic poles and the number of salient poles are both half the number of poles. Also, half the number of magnetic poles has the same polarity, and half the number of salient poles has a different polarity from the magnetic pole.
  • the number of permanent magnets is half of the normal number.
  • the continuous pole type rotor there is a problem that the inductance differs between the magnetic pole and the salient pole, and vibration and noise increase due to the imbalance of the inductance.
  • Patent Document 1 attempts to improve inductance asymmetry and reduce vibration noise by devising a flux barrier shape at both ends of a permanent magnet in a continuous pole type rotor.
  • a flux barrier is a space
  • the continuous pole type rotor has half the number of magnets as compared with a normal IPM type rotor using permanent magnets corresponding to the total number of poles. Therefore, in the continuous pole type rotor, the circumferential width of the bridge existing between adjacent permanent magnets is relatively widened, and the bridge is less likely to be saturated with magnetic flux. Therefore, the magnetic resistance by the bridge is smaller than that of a normal IPM type rotor. As a result, in the continuous pole type rotor, the leakage magnetic flux generated at one of the N or S poles of the permanent magnet flows to the other of the N or S poles of the permanent magnet via the bridge. As a result, the induced voltage is reduced due to magnetic flux leakage.
  • the present invention has been made in view of the above, and an object of the present invention is to obtain a continuous pole type rotor that improves the efficiency by suppressing a decrease in magnetic force due to magnetic flux leakage while reducing the manufacturing cost. .
  • a continuous pole type rotor includes a permanent magnet, a first protrusion and a second protrusion on the outer peripheral surface. And a first core having a recess formed between the first protrusion and the second protrusion on the outer peripheral surface, and an opening having a permanent magnet inserted therein and an opening communicating with the recess. A hole, a first end formed between the first protrusion and the recess, and a second end formed between the recess and the opening.
  • the consequent pole type rotor according to the present invention has an effect of improving efficiency by suppressing a decrease in magnetic force due to magnetic flux leakage while reducing manufacturing cost.
  • Second sectional view of the continuum pole type rotor according to the first embodiment 11 is a perspective view of a rotor core configured by alternately stacking the first core shown in FIG. 11 and the second core shown in FIG. 12 in the axial direction.
  • Side view of the rotor core shown in FIG. A first core block in which a plurality of first cores shown in FIG. 11 are stacked in the axial direction and a second core block in which a plurality of second cores shown in FIG. 12 are stacked in the axial direction are alternately axial.
  • a first core block in which a plurality of first cores shown in FIG. 11 are stacked in the axial direction and a second core block in which a plurality of second cores shown in FIG. 12 are stacked in the axial direction are stacked in the axial direction.
  • the perspective view of the rotor core comprised as a Side view of the rotor core shown in FIG.
  • step difference formed in the outer peripheral surface of the rotor core shown in FIG. The figure which shows the state in which the corner
  • FIG. 13 A perspective view of the rotor after applying resin to the rotor core shown in FIG. 13, FIG. 15 or FIG. Side view of the rotor shown in FIG.
  • FIG. 1 is a side sectional view of an electric motor according to Embodiment 1.
  • FIG. An electric motor 100 shown in FIG. 1 includes a mold stator 10, a rotor 20, and a metal bracket 30 attached to one end portion in the axial direction of the mold stator 10.
  • the electric motor 100 is a brushless DC motor having a permanent magnet in the rotor 20 and driven by an inverter.
  • the rotor 20 is an internal magnet type and a continuous pole type.
  • the mold stator 10 includes a stator 40 and a mold resin 50 covering the stator 40, and the axial direction of the mold stator 10 coincides with the axial direction of the shaft 23 of the rotor 20.
  • a stator core 41 a stator core 41, a coil 42 wound around the stator core 41, and an insulating portion provided in the stator core 41. 43 and the neutral point terminal 44b provided in the insulating part 43 are shown.
  • the substrate 45 mounted on the insulating portion 43, the lead wire lead-out component 46 assembled to the substrate 45, the lead wire 47 lead out from the lead wire lead-out component 46, and the substrate 45 are mounted.
  • An IC (Integrated Circuit) 49a and a Hall IC 49b mounted on the surface of the substrate 45 on the rotor 20 side are shown.
  • the rotor 20 is mounted on the shaft assembly 27, the resin portion 24 that integrates the rotor 20 body and the shaft assembly 27, and the load side that is attached to the shaft 23 and supported by the bearing support portion 11 of the mold stator 10.
  • a rolling bearing 21 a and an anti-load-side rolling bearing 21 b attached to the shaft 23 and supported by the bracket 30 are provided.
  • the load side 110 represents the end surface side from which the shaft 23 projects out of both end surfaces of the electric motor 100
  • the anti-load side 120 represents the end surface side on which the bracket 30 is provided.
  • the shaft assembly 27 includes an insulating sleeve 26 including a pair of insulating sleeves 26-1 and 26-2, and the insulating sleeve 26 is disposed between the anti-load side rolling bearing 21 b and the shaft 23.
  • FIG. 2 is a side sectional view of the mold stator shown in FIG.
  • the mold stator 10 has an opening 10b at one axial end of the mold stator 10, and the rotor 20 is inserted into the opening 10b.
  • a hole 11a larger than the diameter of the shaft assembly 27 of the rotor 20 shown in FIG. 1 is formed at the axial end of the mold stator 10 into which the load-side rolling bearing 21a of the rotor 20 inserted into the opening 10b is fitted. Is opened.
  • Other configurations of the mold stator 10 will be described later.
  • FIG. 3 is a side sectional view showing a state in which the rotor is inserted into the mold stator shown in FIG. 3, the same components as those in FIG. 1 are denoted by the same reference numerals.
  • the rotor 20 inserted from the opening 10b of the mold stator 10 shown in FIG. 2 is arranged so that the load side of the shaft assembly 27 passes through the hole 11a shown in FIG.
  • the At this time, the load-side rolling bearing 21 a attached to the shaft 23 is pushed in until it abuts on the bearing support portion 11 of the mold stator 10 and is supported by the bearing support portion 11.
  • the bearing support portion 11 is an axial end portion of the mold stator 10 and is provided on the opposite side of the opening portion 10b.
  • the anti-load-side rolling bearing 21b is attached to the anti-load side of the shaft assembly 27.
  • the anti-load-side rolling bearing 21b is generally attached by press fitting.
  • an insulating sleeve 26 formed integrally with the shaft 23 is provided between the anti-load side rolling bearing 21b and the anti-load side of the shaft 23.
  • FIG. 4 is a side sectional view of the bracket shown in FIG.
  • the bracket 30 closes the opening 10 b of the mold stator 10 and supports the anti-load side rolling bearing 21 b and is press-fitted into the mold stator 10.
  • the bracket 30 includes a bearing support portion 30a and a press-fit portion 30b formed integrally with the bearing support portion 30a.
  • the bearing support portion 30a supports the anti-load side rolling bearing 21b.
  • the press-fit portion 30b has a ring shape.
  • the mounting of the bracket 30 to the mold stator 10 is performed by press-fitting the press-fit portion 30b into the opening 10b side of the inner peripheral portion 10a of the mold stator 10.
  • the outer diameter of the press-fit portion 30b is larger than the inner diameter of the inner peripheral portion 10a of the mold stator 10 by the press-fit allowance.
  • the bracket 30 is made of a metal having conductivity, and is formed from, for example, a galvanized steel plate. However, the bracket 30 can also be formed from materials other than a galvanized steel plate. Examples of the material of the bracket 30 include an aluminum alloy, an austenitic stainless alloy, a copper alloy, cast iron, steel, or an iron alloy.
  • the mold stator 10 shown in FIG. 2 includes a stator 40 and a mold resin 50 for molding.
  • An unsaturated polyester resin is used for the mold resin 50.
  • a bulk clay thermosetting resin (BMC) obtained by adding various additives to an unsaturated polyester resin is desirable for an electric motor.
  • a thermoplastic resin such as polybutylene terephthalate (PBT) or polyphenylene sulfide (PPS) has a good aspect because a runner at the time of molding can be recycled.
  • the unsaturated polyester resin and BMC have a linear expansion coefficient close to that of ferrous materials such as the stator core 41, the load side rolling bearing 21a, and the anti-load side rolling bearing 21b, and the thermal shrinkage rate is 1 of the thermoplastic resin. / 10 or less is excellent for obtaining dimensional accuracy.
  • the heat dissipation is excellent when the outer shell of the electric motor 100 is formed of unsaturated polyester resin and BMC. Further, when the outer shell of the electric motor 100 is formed of metal, the metal forming the outer shell of the electric motor 100 is separated from the coil 42 and the substrate 45 due to an insulating problem. On the other hand, since unsaturated polyester resin and BMC are insulators, there is no problem of insulation even when the coil 42 and the substrate 45 are covered, and since heat conductivity is high, the heat dissipation is excellent, and the high output of the electric motor 100 is high. Contribute to
  • the load side rolling bearing 21 a is supported by the bearing support portion 11 formed of the mold resin 50, and the anti-load side rolling bearing 21 b and the bracket 30 are supported by the inner peripheral portion 10 a formed of the mold resin 50.
  • the axis of the rotor 20 and the axis of the stator 40 are deviated to cause vibration and noise.
  • an unsaturated polyester resin and BMC having a small heat shrinkage rate it becomes easy to ensure dimensional accuracy after molding.
  • Unsaturated polyester resin and BMC have linear expansion coefficients that are close to the linear expansion coefficients of ferrous materials such as the stator core 41, the load-side rolling bearing 21a, and the anti-load-side rolling bearing 21b. Deviation between the axis of the child 20 and the axis of the stator 40 can be suppressed.
  • the unsaturated polyester resin and BMC restrain the stator 40 when cured, the deformation of the stator 40 due to the excitation force of the electric motor 100 can be suppressed, and vibration and noise can be suppressed.
  • FIG. 5 is a configuration diagram of a stator core configured by a plurality of divided core portions and developed in a band shape.
  • the stator core 41 shown in FIG. 5 has a plurality of divided core portions 400 arranged so that each of the plurality of divided core portions 400 is in contact with another adjacent one of the plurality of divided core portions 400.
  • Each of the plurality of divided core portions 400 includes a back yoke 401 and teeth 402 protruding from the back yoke 401. Between adjacent back yokes 401, a thin portion 403 that connects the back yokes 401 is provided.
  • FIG. 6 is a diagram showing a state in which the developed stator core shown in FIG. 5 is bent and configured in an annular shape.
  • the annular stator core 41 shown in FIG. 6 is formed into an annular shape by folding the belt-shaped divided core portion 400 group at the thin-walled portion 403 after the coils 42 of FIG. 1 are applied to each of the plurality of teeth 402 shown in FIG. Formed.
  • the stator core 41 composed of a plurality of divided core portions 400 can be wound with the coil 42 in a state where the coil 42 is unfolded, so that the coil 42 can be densified and highly efficient. It is effective for conversion.
  • the split core portion 400 is connected by the thin wall portion 403, the rigidity of the stator core 41 when it is formed in an annular shape is weak, and those having a large excitation force such as the continuous pole type electric motor 100 are not suitable. It is effective to mold the stator core 41 with a saturated polyester resin, that is, to cover the stator core 41 with an unsaturated polyester resin.
  • stator core 41 composed of a plurality of divided core portions 400 has irregularities at the end of the back yoke 401 in addition to the structure in which the adjacent back yokes 401 are connected by the thin portion 403 as shown in FIG. It may have a structure in which a dowel is formed and the dowels are connected to each other, or a plurality of back yokes 401 separated from each other may be fixed by welding or fitting.
  • the thickness from the inner peripheral portion 41-2 of the stator core 41 to the inner peripheral portion 10-2 of the unsaturated polyester resin is T2
  • the mold stator 10 satisfies the relationship of T1> T2. It is desirable to configure as follows.
  • the rigidity of the radially outer thickness T1 is increased by making the thickness T1 larger than the thickness T2.
  • “Radial direction” indicates the radial direction of the rotor 20.
  • the influence of the excitation force acting on the teeth 402 can be suppressed by providing the unsaturated polyester resin on the divided surface 404 between the adjacent divided core portions 400.
  • holes 405 are formed in the split surface 404 of the annular stator core 41 shown in FIG.
  • the hole 405 is formed by providing a groove or notch between adjacent back yokes 401.
  • the holes 405 are filled with the unsaturated polyester resin.
  • the hole 405 does not need to be filled with unsaturated polyester in the entire region from one end surface to the other end surface in the axial direction of the stator core 41, and is slightly filled from one end surface in the axial direction of the stator core 41. Even in this case, the effect of damping the vibration can be expected.
  • the hole 405 is enlarged to increase the filling amount, the magnetic effect is adversely affected. Therefore, the filling amount is appropriately determined. It is to be noted that the same effect can be obtained even if the hole 405 of the dividing surface 404 has a groove shape opened on the outer peripheral surface of the stator core 41 or a groove shape opened on the slot 406 side.
  • FIG. 7 is a cross-sectional view of a rotor in which all the magnetic poles are composed of permanent magnets.
  • FIG. 8 is a partially enlarged view of the rotor shown in FIG.
  • the rotor 20A shown in FIG. 7 is disposed in each of the annular rotor core 5A, 10 magnet insertion holes 2A formed in the circumferential direction of the rotor core 5A, and 10 magnet insertion holes 2A. 10 permanent magnets 1A.
  • “Circumferential direction” indicates the circumferential direction of the rotor 20A.
  • the rotor core 5A is composed of a core material that is a soft magnetic material, and is formed by laminating a plurality of electromagnetic steel plates.
  • the permanent magnet 1A is a flat-plate rare earth magnet having a rectangular cross section, and is a neodymium sintered magnet mainly composed of Nd (neodymium) -Fe (iron) -B (boron).
  • the magnet insertion hole 2A is composed of a rectangular first region 3A in which the permanent magnet 1A is inserted and two second regions 3B in which the permanent magnet 1A is not inserted.
  • the second region 3B is a first region 3B. One region is formed at each end in the longitudinal direction of the region 3A.
  • the second region 3B has a function of a flux barrier that suppresses the leakage flux with respect to the permanent magnet 1A inserted in the first region 3A, and the magnetic flux density distribution on the outer peripheral surface 51 of the rotor core 5A. It has the function of short-circuiting the magnetic flux of the permanent magnet 1A inserted in the adjacent magnet insertion hole 2A via the rotor core 5A, close to a sine wave.
  • the ten magnet insertion holes 2A are arranged at equal intervals in the circumferential direction of the rotor core 5A, and are arranged at equal distances from the rotating shaft 6. Adjacent magnet insertion holes 2A are separated from each other.
  • the rotating shaft 6 coincides with the axis of the rotor core 5A.
  • the magnet insertion hole 2A is formed near the outer peripheral surface 51 of the rotor core 5A and penetrates in the axial direction of the rotor core 5A.
  • the rotor core 5A has a bridge 4A1 and a bridge 4A2.
  • the bridge 4A1 is formed between the radially outer side of the second region 3B of the magnet insertion hole 2A and the outer peripheral surface 51 of the rotor core 5A, and the bridge 4A2 is adjacent to the second region 3B of the magnet insertion hole 2A. It is formed between the second region 3B of the magnet insertion hole 2A.
  • the rotor core 5A has a shaft insertion hole 7 in the center.
  • the thickness t1 in the radial direction of the bridge 4A2 is the same as the thickness t2 in the circumferential direction of the bridge 4A1, or slightly thicker than the thickness t2 in the circumferential direction of the bridge 4A1.
  • N poles and S poles are arranged on the radially outer side of each of the adjacent permanent magnets 1A, that is, on the outer peripheral surface 51 side. Therefore, leakage magnetic flux a flows from one N pole to the other S pole. At this time, in the rotor 20A, since the bridge 4A1 and the bridge 4A2 become magnetic resistances, the amount of leakage magnetic flux is suppressed.
  • FIG. 9 is a sectional view of a general consequent pole type rotor.
  • FIG. 10 is a partially enlarged view of the rotor shown in FIG.
  • a rotor 20B shown in FIG. 9 has an annular rotor core 5B and five magnet insertion holes 2B arranged in the circumferential direction.
  • the number of magnet insertion holes 2B is half the number of poles of the rotor 20B.
  • the five magnet insertion holes 2B are arranged at equal intervals in the circumferential direction.
  • the five magnet insertion holes 2 ⁇ / b> B are arranged at an equal distance from the rotation shaft 6.
  • the rotating shaft 6 coincides with the axis of the rotor core 5B.
  • the five magnet insertion holes 2B penetrate in the axial direction of the rotor core 5B.
  • the magnet insertion hole 2B is formed near the outer peripheral surface 51 of the rotor core 5B and extends in the circumferential direction. Adjacent magnet insertion holes 2B are spaced apart.
  • the rotor core 5B has a shaft insertion hole 7 at the center.
  • the rotor core 5B is composed of a core material that is a soft magnetic material, and is specifically composed by laminating a plurality of electromagnetic steel sheets.
  • the thickness of the electromagnetic steel sheet is generally 0.1 mm to 0.7 mm.
  • the permanent magnet 1B is a flat plate having a rectangular cross section, for example.
  • the plate thickness of the permanent magnet 1B is 2 mm, for example.
  • the permanent magnet 1B is a rare earth magnet and is a neodymium sintered magnet mainly composed of Nd (neodymium) -Fe (iron) -B (boron).
  • the magnet insertion hole 2B includes a rectangular first region 3A into which the permanent magnet 1B is inserted and two second regions 3B into which the permanent magnet 1B is not inserted.
  • the second region 3B is a first region 3B. One region is formed at each end in the longitudinal direction of the region 3A.
  • the second region 3B has a function of a flux barrier that suppresses the leakage magnetic flux a with respect to the permanent magnet 1B inserted in the first region 3A, and the magnetic flux density distribution on the outer peripheral surface 51 of the rotor core 5B. Is brought close to a sine wave, and the magnetic flux of the permanent magnet 1B inserted into the adjacent magnet insertion hole 2B is short-circuited through the rotor core 5B.
  • the rotor 20B has ten magnetic poles arranged on the outer peripheral surface 51 of the rotor core 5B so that the polarities are alternately arranged in the circumferential direction.
  • the rotor 20B is formed on five rotor poles 5B between the permanent magnets 1B adjacent to each other and five first magnetic poles each having the same polarity and formed by five permanent magnets 1B. It has five second magnetic poles having different polarities from the first magnetic poles.
  • the first magnetic pole is an N pole and the second magnetic pole is an S pole, but may be reversed.
  • the five permanent magnets 1B which are half the number of poles, each provide five first magnetic poles.
  • each of the five second magnetic poles which is half the number of poles, is formed on the core material of the rotor core 5B between the adjacent permanent magnets 1B.
  • the second magnetic pole is a so-called salient pole, and is formed by magnetizing the rotor 20B.
  • the first magnetic pole portion 60 that has the first magnetic pole and the magnet magnetic pole portion including the permanent magnet 1B, and the core magnetic pole portion that does not include the permanent magnet 1B and has the second magnetic pole portion.
  • the second magnetic pole portions 61 are alternately arranged in the circumferential direction of the rotor 20B.
  • the number of poles is an even number of 4 or more.
  • the outer shape of the rotor core 5B is a so-called flower circle shape.
  • the flower-circle shape is a shape in which the outer diameter of the rotor core 5B is maximum at the pole centers 62 and 63 and is minimum at the distance 64, and the arc from the pole centers 62 and 63 to the distance 64 is arc-shaped. It is.
  • the pole center 62 is the pole center of the first magnetic pole
  • the pole center 63 is the pole center of the second magnetic pole.
  • the flower circle shape is a shape in which ten petals of the same shape and the same size are arranged at an equal angle. Accordingly, the outer diameter of the rotor core 5B at the pole center 62 is equal to the outer diameter of the rotor core 5B at the pole center 63.
  • the circumferential width of the magnet insertion hole 2B is wider than the pole pitch.
  • the rotor core 5B has a bridge 5B1 and a bridge 5B2.
  • the bridge 5B1 is formed between the radially outer side of the second region 3B of the magnet insertion hole 2B and the outer peripheral surface 51 of the rotor core 5B, and the bridge 5B2 includes the second region 3B of the magnet insertion hole 2B, It is formed between the second regions 3B of the adjacent magnet insertion holes 2B.
  • Consequent pole type rotor 20B configured in this way has an outer magnetic pole of each of adjacent permanent magnets 1B having N and N poles, and the circumferential width of bridge 5B2 between adjacent permanent magnets 1B. Is wider than the circumferential width of the bridge 4A2 formed in the rotor 20A shown in FIG. Accordingly, the distance between the adjacent bridges 5B1 increases via the bridge 5B2, and the path of the leakage magnetic flux a leaked from one bridge 5B1 does not reach the other adjacent bridge 5B1, so that the leakage magnetic flux a passes through only one bridge 5B1. It passes through and leaks to the south pole of the permanent magnet 1B.
  • the magnetic resistance due to the bridge 5B1 is smaller than that of a normal IPM, the magnetic flux generated at the N pole of one permanent magnet 1B among the adjacent permanent magnets 1B is changed to that of the one permanent magnet 1B.
  • the leakage magnetic flux is increased.
  • the thickness of the bridge 5B1 is limited to make it thin for the convenience of processing at the time of manufacturing the core piece constituting the rotor core 5B. Therefore, as the size of the motor is reduced, the size of the rotor and the permanent magnet are reduced. The ratio of the size of the bridge 5B1 to the size of is increased, and the influence of the leakage magnetic flux a is further increased. When the leakage magnetic flux a increases, the current for generating the torque of the electric motor increases, resulting in a reduction in electric motor efficiency.
  • FIG. 11 is a first cross-sectional view of the continuum pole type rotor according to the first embodiment.
  • FIG. 12 is a second cross-sectional view of the continuum pole type rotor according to the first embodiment.
  • FIG. 13 is a perspective view of a rotor core configured by alternately stacking the first core shown in FIG. 11 and the second core shown in FIG. 12 in the axial direction.
  • 14 is a side view of the rotor core shown in FIG.
  • FIG. 15 shows alternating first core blocks in which a plurality of first cores shown in FIG. 11 are stacked in the axial direction and second core blocks in which a plurality of second cores shown in FIG.
  • FIG. 12 It is a perspective view of the rotor core comprised by laminating
  • 16 is a side view of the rotor core shown in FIG. 17 shows a first core block in which a plurality of first cores shown in FIG. 11 are stacked in the axial direction, and a second core block in which a plurality of second cores shown in FIG. 12 are stacked in the axial direction.
  • 18 is a side view of the rotor core shown in FIG.
  • the rotor core 5 of the rotor 20 includes a first core 5-1 and a second core 5-2 that are stacked in the axial direction of the rotor core 5.
  • FIG. 11 shows a cross-sectional view of the first core 5-1
  • FIG. 12 shows a cross-sectional view of the second core 5-2.
  • the first core 5-1 includes a magnet insertion hole 1C which is five first insertion holes arranged in the circumferential direction, a radially outer side of the magnet insertion hole 1C, and an outer circumferential surface of the first core 5-1. 51 and caulking 8 formed in the core portion between them.
  • the magnet insertion hole 1C of the first core 5-1 includes a rectangular first region 3CA in which the permanent magnet 1B is inserted, and two second regions 3CB in which the permanent magnet 1B is not inserted.
  • the second region 3CB is formed at one location at each end in the longitudinal direction of the first region 3CA.
  • the second region 3CB has a function of a flux barrier that suppresses a leakage flux with respect to the permanent magnet 1B inserted in the first region 3CA, and the magnetic flux on the outer peripheral surface 51 of the first core 5-1.
  • the density distribution is made close to a sine wave, and the magnetic flux of the permanent magnet 1B inserted in the adjacent magnet insertion hole 1C is short-circuited via the first core 5-1.
  • one second region 3CB1 opens to the outer peripheral surface 51 of the rotor core 5 and the other first core.
  • the second region 3CB2 of 5-1 does not open to the outer peripheral surface 51 of the rotor core 5, but is closed in the circumferential direction. Since the second region 3CB1 opens in the outer peripheral surface 51 of the rotor core 5 and has a larger magnetic resistance than the closed second region 3CB2, the rotation in which both the second regions are closed Leakage magnetic flux can be reduced compared to the child core.
  • the second core 5-2 includes five second insertion holes arranged in the circumferential direction, ie, a magnet insertion hole 1D, and a radially outer side of the magnet insertion hole 1D. And the caulking 8 formed in the core part between the outer peripheral surface 51 of the second core 5-2.
  • the magnet insertion hole 1D of the second core 5-2 includes a rectangular first area 3DA in which the permanent magnet 1B is inserted and two second areas 3DB in which the permanent magnet 1B is not inserted.
  • the two regions 3DB are formed one at each end in the longitudinal direction of the first region 3DA.
  • the second region 3DB has a function of a flux barrier that suppresses leakage magnetic flux with respect to the permanent magnet 1B inserted in the first region 3DA, and the magnetic flux on the outer peripheral surface 51 of the second core 5-2.
  • the density distribution is brought close to a sine wave, and the magnetic flux of the permanent magnet 1B inserted in the adjacent magnet insertion hole 1D is short-circuited via the second core 5-2.
  • one second region 3DB1 opens in the outer peripheral surface 51 of the rotor core 5 and the other second region 3DB.
  • 3DB2 does not open to the outer peripheral surface 51 of the rotor core 5 but is closed in the circumferential direction. Since the second region 3DB1 opens in the outer peripheral surface 51 of the rotor core 5 and has a larger magnetic resistance than the closed second region 3DB2, the rotation in which both the second regions are closed Leakage magnetic flux can be reduced compared to the child core.
  • the rotor core 5 shown in FIG. 13 and FIG. 14 is configured by alternately laminating first cores 5-1 and second cores 5-2 in the axial direction.
  • the rotor core 5 shown in FIGS. 15 and 16 includes a first core block 5-11 in which a plurality of first cores 5-1 shown in FIG. 11 are stacked in the axial direction, and a second core shown in FIG.
  • the second core block 5-21 in which a plurality of 5-2s are stacked in the axial direction is alternately stacked in the axial direction.
  • the rotor core 5 shown in FIGS. 17 and 18 is configured by laminating a first core block 5-11 and a second core block 5-21 in the axial direction.
  • the bridge 5B1 on one side of the two bridges 5B1 existing on both sides of the permanent magnet 1B shown in FIGS. 10 and 11 is omitted.
  • the bridge 5B1 on one side of the two bridges 5B1 existing on both sides of the permanent magnet 1B shown in FIGS. 10 and 11 is omitted.
  • the range overlapping the first outer peripheral position is the second outer peripheral position, no opening is formed at the second outer peripheral position. Therefore, since there is a position where the opening ranges do not overlap between the first core 5-1 and the second core 5-2, the insufficient strength can be resolved.
  • the rotor core 5 is provided with a caulking 8 that mutually fastens a plurality of cores stacked in the axial direction, so that the plurality of core portions 9 are integrated, and centrifugal force due to rotation is made permanent. It can be held outside the magnet 1B.
  • the number of the first cores 5-1 and the second cores 5-2 may be one or plural, depending on the strength required for the rotor core 5 and the productivity of the rotor core 5. It is determined appropriately.
  • the rotor core 5 has the first core 5-1 and the second core 5-2 in the axial direction of the rotor core 5. It is configured by laminating one or a plurality of third cores having no opening. Although the strength is increased by this configuration, the leakage flux increases as the ratio of the third core increases. Therefore, the number of inserted third cores is determined in consideration of the centrifugal strength and the influence of the leakage flux. .
  • the outer peripheral surface 51 of the rotor core 5 has a circular flower shape with a plurality of protrusions, and the pole center 62 of the first magnetic pole part 60 corresponding to the first protrusion of the rotor core 5B and the rotor core 5B. Between the pole center 63 of the second magnetic pole part 61 corresponding to the second protrusion, a gap 64 corresponding to a depression is provided.
  • the rotor core 5 is difficult to assemble the electric motor due to the flower circle shape.
  • the flower circle shape complicates the jig structure for accurately inserting the rotor into the stator.
  • the air gap changes depending on how the slot opening of the stator core and the flower-shaped protruding part and the retracting part face each other. You must check while changing the rotor position. Therefore, it is preferable for production that the outer diameter of the rotor is close to a perfect circle.
  • the gap 64 corresponding to the flower circle recess is covered with resin in the outer peripheral surface 51 of the rotor core 5, and the second region 3B of the magnet insertion hole is covered with resin. Further, the opening formed in the second region 3B of the magnet insertion hole is covered with resin.
  • FIG. 19 is a view showing a state where resin is applied to the rotor core shown in FIG. 13, FIG. 15 or FIG. 20 is a partially enlarged view of the rotor core shown in FIG.
  • the rotor core 5 includes an outer peripheral surface 71 in which a gap 64 between the first magnetic pole part 60 and the second magnetic pole part 61 is covered with a resin 72.
  • the second region 3CB2 and the second region 3CB1 of the insertion hole are covered with the resin 72.
  • the opening 73 formed in the second region 3CB1 is covered with the resin 72.
  • the second region 3DB2 shown in FIG. 12 is covered with the resin 72
  • the second region 3DB1 is covered with the resin 72.
  • the first magnetic pole part 60 and the second magnetic pole part 60 which are the parts having the largest outer diameter, of the outer peripheral surface 71 of the rotor core 5.
  • the resin 72 covering the outer peripheral surface 71 of the magnetic pole portion 61 is thin, and burrs are generated. As a result, the resin 72 may be peeled off from the rotor core 5.
  • FIG. 21 is a view showing a state where a notch is formed in the rotor core shown in FIG. 13, FIG. 15 or FIG.
  • FIG. 22 is a partially enlarged view of the rotor core shown in FIG.
  • FIG. 23 is a diagram illustrating a state in which the opening, the first cutout, and the second cutout of the rotor core shown in FIG. 22 are covered with resin.
  • 24 is a partially enlarged view of the rotor core shown in FIG.
  • a bridge 5B1 is formed on the right side of the magnet insertion hole 2B, and an opening 73 is formed on the left side of the magnet insertion hole 2B.
  • the rotor core 5 has a first cutout portion 74 and a second cutout portion 75 in the gap 64 between the first magnetic pole portion 60 and the second magnetic pole portion 61 in the outer peripheral surface 71. Is formed.
  • the rotor core 5 includes a bridge 5B1 between the pole center 62 of the first magnetic pole part 60 and the pole center 63 of the second magnetic pole part 61 at one end of the magnet insertion hole 2B in the circumferential direction. And a first notch 74 is formed at one end in the circumferential direction of the bridge 5B1, and a second notch 75 is formed at the other end in the circumferential direction of the bridge 5B1.
  • the rotor core 5 has, at the other end of the magnet insertion hole 2B in the circumferential direction, the pole center 62 of the first magnetic pole portion 60 corresponding to the first protrusion and the second protrusion corresponding to the second protrusion of the rotor core 5B.
  • An opening 73 that communicates with the depression 64 is formed in the gap 64 that corresponds to the depression between the pole center 61 and the pole center 61, and a first notch 74 is formed on one end side in the circumferential direction of the opening 73.
  • a second notch 75 is formed on the other end side of the opening 73.
  • the first cutout portion 74 and the second cutout portion 75 have a radially outer surface convex from the virtual outer peripheral surface 71-1 of the rotor core 5 toward the radially inner side.
  • the first notch 74 is a first end 74a1 formed between a pole center 62 that is a first protrusion and a gap 64 that is a recess. And a second end 74a2 formed between the gap 64 which is a depression and the bridge 5B1.
  • the first notch 74 is a first end formed between the pole center 62 that is the first protrusion and the gap 64 that is the depression.
  • 74b1 and a second end 74b2 formed between the gap 64 which is a depression and the opening 73 of the magnet insertion hole 2B.
  • the first cutout portion 74 of the rotor core 5 By injecting mold resin into the first cutout portion 74, the second cutout portion 75, and the opening 73, the first cutout portion 74 of the rotor core 5 as shown in FIGS.
  • the second notch 75 and the opening 73 are covered with the resin 72.
  • the radial width of the resin 72 covering the opening 73 can be relatively increased. Therefore, generation
  • the centrifugal strength can be assisted by covering with resin 72, the centrifugal strength can be further improved. Further, by covering the permanent magnet with the resin 72, oxygen and moisture do not come into contact with the permanent magnet, and it is possible to prevent aged deterioration of the magnetic force due to corrosion of the permanent magnet.
  • FIG. 25 is a view for explaining steps formed on the outer peripheral surface of the rotor core shown in FIG.
  • the rotor core 5 is formed in a portion where the radius RB of the resin outer peripheral surface 71-3 of the closing resin 72-1 that closes the opening 73 is the largest outer diameter of the rotor core 5.
  • the radius 72 of the resin 72 on the resin outer peripheral surface 71-2 is larger than the radius RA. Accordingly, there is a step 76 between the resin outer peripheral surface 71-3 and the resin outer peripheral surface 71-2.
  • the steps 76 are formed on the first cutout portion 74 side and the second cutout portion 75 side, respectively.
  • the level difference 76 on the first notch 74 side is more circumferential than the position where the end surface 74-1 in the circumferential direction of the first notch 74 is in contact with the closing resin 72-1 formed in the opening 73. Is located on the center 73a side of the opening 73.
  • the step 76 on the second notch 75 side is more circumferential than the position where the end surface 75-1 in the circumferential direction of the second notch 75 is in contact with the closing resin 72-1 formed in the opening 73. Is located on the center 73a side of the opening 73.
  • FIG. 26 is a diagram showing a state in which corners between the resin outer peripheral surface of the plugging resin and the circumferential end surface of the plugging resin shown in FIG. 25 are formed in an R shape or a chamfered shape.
  • the corner portion 71-5 between the resin outer peripheral surface 71-3 of the blocking resin 72-1 and the circumferential end surface 71-4 of the blocking resin 72-1 is formed into an R shape or a chamfered shape.
  • FIG. 27 is a view showing an example in which the resin outer peripheral surface of the blocking resin is formed so as to eliminate the step shown in FIG.
  • the blocking resin 72-1 has a resin outer peripheral surface 71-3 and a resin outer peripheral surface 71- so that the step 76 shown in FIG. 2 has a circular arc surface 71-31 that is continuous with the arc.
  • FIG. 28 is a view showing a mold for restraining the outer peripheral surface of the rotor core according to the present embodiment from the radial direction.
  • the corner portion 71-5 between the resin outer peripheral surface 71-3 of the closing resin 72-1 and the circumferential end surface 71-4 of the closing resin 72-1 is formed into an R shape or a chamfered shape.
  • a state and a state after the corner portion 71-5 is formed into an R shape or a chamfered shape are shown.
  • an R shape or chamfered contact surface 81a can be provided on the mold 80.
  • the shapes of the first notch portion 74 and the second notch portion 75 are appropriately determined so that the thickness of the resin 72 can be secured to a certain value or more, for example, 0.5 mm or more.
  • the shape of the corner 71-5 of the surface 71-2 is appropriately determined.
  • FIG. 29 is a perspective view of the rotor after resin is applied to the rotor core shown in FIG. 13, FIG. 15 or FIG. 30 is a side view of the rotor shown in FIG.
  • the resin 72 when the outer peripheral surface of the rotor core 5 is suppressed from the radial direction by a mold when the resin 72 is filled, the resin leakage to the outer peripheral surface of the rotor core 5 is suppressed. It is also possible to improve the quality by using a slide mold using an angular structure. Further, when the resin 72 is injected, by positioning the resin injection gate on the inner diameter side of the bridge 5B1, the resin injection pressure to the resin injection portion can be increased, and the product can be manufactured stably.
  • the distance from the axial center A of the rotor core 5 constituting the rotor 20 to the resin outer peripheral surface 71-2 where the outer diameter of the rotor core 5 becomes larger is X
  • the closing resin 72 from the axial center A of the rotor core 5 is X.
  • ⁇ 1 where Y is the distance to the resin outer peripheral surface 71-3, X and Y have a relationship of X ⁇ Y.
  • FIG. FIG. 31 is a diagram illustrating an example of a configuration of an air conditioner according to Embodiment 2.
  • the air conditioner 300 includes an indoor unit 310 and an outdoor unit 320 connected to the indoor unit 310.
  • An indoor unit blower (not shown) is mounted on the indoor unit 310, and an outdoor unit blower 330 is mounted on the outdoor unit 320.
  • the outdoor unit 320 is equipped with a compressor (not shown).
  • the electric motor 100 which concerns on Embodiment 1 is used for these air blowers and compressors.
  • the electric motor 100 according to Embodiment 1 as a drive source for the blower and compressor of the air conditioner 300, it is possible to reduce the cost, vibration, and noise of the air conditioner 300. it can.
  • the electric motor 100 according to the first embodiment can be mounted on an electric device other than the air conditioner, and in this case, the same effect as that of the present embodiment can be obtained.
  • the configuration described in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and can be combined with other configurations without departing from the gist of the present invention. It is also possible to omit or change the part.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

La présente invention concerne un rotor à pôles conséquents qui comprend un premier noyau ayant un centre de pôle (62) et un centre de pôle (63) sur la surface circonférentielle externe (71), le premier noyau ayant : un intervalle de pôle (64) agencé, dans la surface circonférentielle externe (71), entre le centre de pôle (62) et le centre de pôle (63) ; un trou d'insertion d'aimant (2B) dans lequel est inséré un aimant permanent et qui possède une ouverture (73) dans l'intervalle de pôle (64) ; une première extrémité (74a1) formée entre le centre de pôle (62) et l'intervalle de pôle (64) ; une seconde extrémité (74a2) formée entre l'intervalle de pôle (64) et l'ouverture (73). Par conséquent, une réduction de la force magnétique due à une fuite de flux magnétique peut être supprimée de façon à améliorer l'efficacité, tout en réduisant les coûts de fabrication.
PCT/JP2016/073135 2016-08-05 2016-08-05 Rotor à pôles conséquents, moteur électrique et climatiseur WO2018025407A1 (fr)

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PCT/JP2016/073135 WO2018025407A1 (fr) 2016-08-05 2016-08-05 Rotor à pôles conséquents, moteur électrique et climatiseur
JP2018531715A JP6545387B2 (ja) 2016-08-05 2016-08-05 コンシクエントポール型の回転子、電動機および空気調和機

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PCT/JP2016/073135 WO2018025407A1 (fr) 2016-08-05 2016-08-05 Rotor à pôles conséquents, moteur électrique et climatiseur

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180287439A1 (en) * 2017-03-29 2018-10-04 Ford Global Technologies, Llc Permanent magnet electric machine
JP2020014322A (ja) * 2018-07-18 2020-01-23 日立オートモティブシステムズ株式会社 回転電機のロータおよび回転電機
WO2020090007A1 (fr) * 2018-10-30 2020-05-07 三菱電機株式会社 Rotor à pôles conséquents, moteur électrique, ventilateur, dispositif de réfrigération et de climatisation ainsi que procédé de fabrication de rotor à pôles conséquents
US20210091617A1 (en) * 2019-09-25 2021-03-25 Samsung Electronics Co., Ltd. Rotor and motor including the same
WO2023209851A1 (fr) * 2022-04-27 2023-11-02 株式会社 東芝 Rotor à aimant permanent intérieur et machine électrique tournante

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JP2012151970A (ja) * 2011-01-18 2012-08-09 Asmo Co Ltd 磁石埋込型ロータ、及びモータ
JP2013192336A (ja) * 2012-03-13 2013-09-26 Asmo Co Ltd ロータ及びモータ
JP2013230070A (ja) * 2011-10-28 2013-11-07 Asmo Co Ltd ロータ及びモータ

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JP5279777B2 (ja) * 2010-08-28 2013-09-04 三菱電機株式会社 同期電動機の回転子

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Publication number Priority date Publication date Assignee Title
JP2012151970A (ja) * 2011-01-18 2012-08-09 Asmo Co Ltd 磁石埋込型ロータ、及びモータ
JP2013230070A (ja) * 2011-10-28 2013-11-07 Asmo Co Ltd ロータ及びモータ
JP2013192336A (ja) * 2012-03-13 2013-09-26 Asmo Co Ltd ロータ及びモータ

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180287439A1 (en) * 2017-03-29 2018-10-04 Ford Global Technologies, Llc Permanent magnet electric machine
JP2020014322A (ja) * 2018-07-18 2020-01-23 日立オートモティブシステムズ株式会社 回転電機のロータおよび回転電機
WO2020017262A1 (fr) * 2018-07-18 2020-01-23 日立オートモティブシステムズ株式会社 Rotor pour machine dynamoélectrique et machine dynamoélectrique
WO2020090007A1 (fr) * 2018-10-30 2020-05-07 三菱電機株式会社 Rotor à pôles conséquents, moteur électrique, ventilateur, dispositif de réfrigération et de climatisation ainsi que procédé de fabrication de rotor à pôles conséquents
JPWO2020090007A1 (ja) * 2018-10-30 2021-04-30 三菱電機株式会社 回転子、コンシクエントポール型回転子、電動機、送風機、冷凍空調装置、回転子の製造方法、及びコンシクエントポール型回転子の製造方法
US20210091617A1 (en) * 2019-09-25 2021-03-25 Samsung Electronics Co., Ltd. Rotor and motor including the same
US11594923B2 (en) * 2019-09-25 2023-02-28 Samsung Electronics Co., Ltd. Rotor and motor including the same
WO2023209851A1 (fr) * 2022-04-27 2023-11-02 株式会社 東芝 Rotor à aimant permanent intérieur et machine électrique tournante

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