WO2018221008A1 - 回転子、回転電機、および回転子の製造方法 - Google Patents
回転子、回転電機、および回転子の製造方法 Download PDFInfo
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- WO2018221008A1 WO2018221008A1 PCT/JP2018/014741 JP2018014741W WO2018221008A1 WO 2018221008 A1 WO2018221008 A1 WO 2018221008A1 JP 2018014741 W JP2018014741 W JP 2018014741W WO 2018221008 A1 WO2018221008 A1 WO 2018221008A1
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- Prior art keywords
- rotor
- protective ring
- permanent magnet
- axial direction
- protective
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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
- H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
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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
- H02K1/2753—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 or groups of magnets arranged with alternating polarity
- H02K1/278—Surface mounted magnets; Inset magnets
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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
-
- 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
- H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
- H02K1/30—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures using intermediate parts, e.g. spiders
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
- H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
- H02K21/14—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
- H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
- H02K21/14—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures
- H02K21/145—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures having an annular armature coil
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/02—Details of the magnetic circuit characterised by the magnetic material
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
Definitions
- This application relates to a rotor of a rotating electrical machine in which a permanent magnet is provided on the rotor, a rotating electrical machine, and a method of manufacturing the rotor.
- a steel magnetic ring located on the inner peripheral side and CFRP (Carbon Fiber Reinforced Plastics) located on the outer peripheral side.
- CFRP Carbon Fiber Reinforced Plastics
- a rotor member including a layer, a plurality of permanent magnets sandwiched between the magnetic ring and the CFRP layer, and a rotating shaft, and the rotor member is fitted to the rotating shaft by a hydraulic fit.
- the magnetic ring leaves a clamping force with respect to the rotation shaft even during high-speed rotation (see, for example, Patent Document 1).
- the CFRP layer is formed by directly winding CFRP around an outer periphery of a permanent magnet in which a plurality of sintered permanent magnet rings are connected while being impregnated with an adhesive resin. It is shown that the resin is cured to form an integrated structure, and then the folded portions and dummy pieces at both ends of the CFRP layer are removed and cut into a predetermined length.
- sintered magnets are easily cracked by processing, it is difficult to cut out the CFRP layer to the same surface as the end surface of the permanent magnet. Therefore, a space where no permanent magnet exists in the inner peripheral portion of the end portion of the CFRP layer remains. .
- the rotor having such a space has a problem that the CFRP layer on the end surface of the permanent magnet may be damaged by stress concentration during high-speed rotation.
- the present application discloses a technique for solving the above-described problems, prevents damage to the protective cover due to centrifugal force during rotation, makes it possible to suppress peeling of the permanent magnet, and rotation with improved reliability.
- An object is to provide a rotor, a rotating electrical machine, and a method of manufacturing the rotor.
- the rotor disclosed in this application is Around the shaft, a plurality of permanent magnets divided at equal intervals in the circumferential direction and provided in the axial direction; A first protective ring that positions and holds one end of the permanent magnet in the axial direction; A second protective ring that positions and holds the other end of the permanent magnet in the axial direction; The permanent magnet, the first protective ring, and a protective cover having a uniform thickness in the radial direction covering the outer peripheral surface of the second protective ring.
- the rotating electrical machine disclosed in the present application is A stator, The above-described rotor is rotatably supported inside the stator.
- the pressurizing step includes bringing the first protective ring, the permanent magnet, and the second protective ring into close contact in the axial direction.
- the rotor disclosed in the present application since there is no space in the inner peripheral portion of the end portion of the cover where no permanent magnet exists, there is no fear of the cover being damaged due to stress concentration, and a highly reliable rotor is provided. it can.
- FIG. 3 is a longitudinal sectional view of the rotor according to the first embodiment.
- FIG. 2 is a cross-sectional view taken along the line XX of FIG. 1 according to the first embodiment. It is a cross-sectional schematic diagram which shows the state which assembled the magnet assembly using the core temporarily installed on the exclusive jig
- FIG. 5 is a diagram illustrating an assembly flow of the rotor according to the first embodiment.
- FIG. 6 is a longitudinal sectional view of another example of the rotor according to the first embodiment. It is a cross-sectional schematic diagram which shows the state which assembled the magnet assembly using the core temporarily installed on the exclusive jig
- FIG. 10 is a diagram illustrating an assembly flow of a rotor according to a second embodiment.
- FIG. 6 is a longitudinal sectional view of a main part of a rotor according to a third embodiment.
- FIG. 10 is a diagram illustrating an assembly flow of a rotor according to a third embodiment. 6 is a schematic side view of a protective cover according to Embodiment 3.
- FIG. 6 is a longitudinal sectional view of a rotor according to a fourth embodiment.
- FIG. 10 is a diagram illustrating an assembly flow of a rotor according to a fourth embodiment.
- FIG. 10 is a longitudinal sectional view of a rotating electrical machine according to a fifth embodiment.
- FIG. 10 is a longitudinal sectional view of a main part of a rotor according to a sixth embodiment.
- FIG. 1 is a longitudinal sectional view of a rotor 1 according to the first embodiment.
- FIG. 2 is a cross-sectional view taken along the line XX of FIG.
- the rotor 1 is provided on a shaft 2, and a cylindrical core 3 having a radially extending flange 3 ⁇ / b> A formed at one end of the core 3.
- a plurality of permanent magnets 4 are provided on the outer peripheral surface, that is, the permanent magnets 4 are arranged in the axial direction via spacers 5 so as to be divided in the circumferential direction into N poles and S poles alternately at equal intervals. Further, the permanent magnet 4 is divided into two in the axial direction, and a total of eight permanent magnets 4A including four lower permanent magnets 4A provided at the lower part of the drawing in FIG. 1 and four upper permanent magnets 4B provided at the upper part. It consists of a permanent magnet. Similarly to the permanent magnet 4, the spacer 5 may also be divided into two in the axial direction. The cross-sectional shape shown in FIG.
- the configuration in which the permanent magnet 4 is divided and arranged without the spacer 5 and without a gap in the circumferential direction also functions as the rotor 1.
- a first protective ring 6A is provided between the permanent magnet 4 provided on the core 3 and the flange 3A formed at one end of the core 3. Further, a second protective ring 6 is provided at the upper end in the axial direction of the permanent magnet 4 so as to face the first protective ring 6A.
- the first protective ring 6 ⁇ / b> A and the second protective ring 6 have a function of positioning and holding the axial end of the permanent magnet 4.
- the first protective ring 6A, the second protective ring 6 and the permanent magnet 4 are all in contact with the outer peripheral surface of the same core 3.
- a protective cover 8 is provided on the outer periphery of the first protective ring 6 ⁇ / b> A, the second protective ring 6, and the permanent magnet 4. As shown in FIGS. 1 and 2, the protective cover 8 covers the outer peripheral surfaces of the first protective ring 6 ⁇ / b> A, the second protective ring 6, the permanent magnet 4, and the spacer 5.
- the protective cover 8 has a uniform thickness in the radial direction.
- the core 3 is a magnetic body, and is, for example, a laminated body of annular thin plates obtained by punching electromagnetic steel plates. Instead of this, a steel pipe or a dust core may be used.
- the permanent magnet 4 is a rare earth magnet and may be a ferrite magnet.
- the spacer 5 is made of a nonmagnetic stainless steel, but may be an aluminum alloy, a copper alloy, or a resin.
- the first protective ring 6A and the second protective ring 6 are made of nonmagnetic stainless steel, but may be aluminum alloy, copper alloy, titanium, titanium alloy, or resin.
- the permanent magnet 4 is applied to the inner peripheral surface of the protective cover 8 more evenly.
- the density of the first protective ring 6A and the density of the second protective ring 6 should be close.
- the permanent magnet 4 is a neodymium magnet (density 7.3 to 7.5 g / cm3)
- the first protective ring 6A and the second protective ring 6 are made of stainless steel (density 7.75 to 7.98 g / cm3). Is a preferred combination.
- the protective cover 8 is formed by directly winding a fiber bundle of carbon fiber reinforced plastic (CFRP), and a fiber bundle of glass fiber reinforced plastic (GFRP) may be used in place of CFRP. . Further, instead of the above-described fiber bundle, tape-like CFRP or GFRP may be used.
- CFRP carbon fiber reinforced plastic
- GFRP glass fiber reinforced plastic
- FIG. 3 is a schematic cross-sectional view showing a state in which the magnet assembly 40 is assembled using the core 3 temporarily installed on the dedicated jig 20.
- FIG. 4 is a diagram illustrating an assembly flow of the rotor 1 including the magnet assembly 40.
- the magnet assembly 40 is formed by integrally forming the first protective ring 6A, the second protective ring 6, the permanent magnet 4, the spacer 5, and the protective cover 8 on the outer peripheral surface of the core 3.
- a manufacturing method will be described for each step (abbreviated as ST).
- the dedicated jig 20 is installed in the rotation drive device 30 (jig installation process).
- the core 3 is fixed to the dedicated jig 20 with a fixing tool (not shown) (core fixing step).
- the first protective ring 6A is installed so as to contact the flange 3A of the core 3 (first protective ring installation step).
- a plurality of lower permanent magnets 4A and spacers 5 are attached to the outer peripheral surface of the core 3 with an adhesive so that the lower ends of the first protective ring 6A are in contact with each other (lower permanent magnet and spacer bonding step). .
- the lower permanent magnets 4A are arranged so that the N poles and the S poles are alternately placed in the circumferential direction via the spacers 5.
- the plurality of upper permanent magnets 4B and the spacers 5 are attached to the outer peripheral surface of the core 3 using an adhesive (upper permanent magnet and spacer bonding step).
- the second protective ring 6 is attached to the outer peripheral surface of the core 3 using an adhesive so as to be in contact with the axial end surface of the upper permanent magnet 4B (second protective ring bonding step).
- ST6A A pressure jig 20A for pressing the second protective ring 6 in the axial direction is attached to the upper side of the second protective ring 6 in the axial direction, and the second protective ring 6 is pressed in the axial direction before the adhesive is cured ( Pressure step).
- the rotation driving device 30 is operated, the dedicated jig 20 is driven to rotate, a fiber bundle made of glass fiber or carbon fiber is spirally wound in the axial direction (filament winding), and an epoxy resin for adhesion is impregnated.
- the first protective ring 6A, the permanent magnet 4, the spacer 5, and the second protective ring 6 are uniformly wound on the outer peripheral surface (fiber bundle winding step).
- the winding direction may be from FIG. 3, from the top to the bottom of the paper, or from the bottom to the top.
- a tape-like fiber material impregnated with the resin in advance may be used instead of winding the fiber bundle while impregnating the resin.
- the range in which the fiber bundle is wound is regulated from both sides in the axial direction by the end regulating jig 20B. Thereby, it is possible to prevent the resin impregnated in the fiber material from spreading in the axial direction.
- ST7A A heat-shrinkable tape (not shown) that is shrunk by heat is wound around the outer circumference of the wound CFRP fiber bundle (heat-shrinkable tape winding step). The heat shrink tape prevents the resin from sagging in the circumferential direction. Thereby, the protective cover 8 having a uniform thickness can be obtained.
- the epoxy resin is cured in a furnace (curing process). ST9.
- the magnet assembly 40 fixed integrally is removed from the dedicated jig 20 (extraction process).
- the heat shrink tape is removed from the outer periphery of the magnet assembly 40 (heat shrink tape removal step).
- the rotor 2 shown in FIG. 1 is manufactured by fitting and fixing the shaft 2 to the magnet assembly 40 by press-fitting (shaft press-fitting process).
- an epoxy resin is used from the viewpoint of strength and rigidity.
- good performance can be obtained with vinyl ester, unsaturated polyester, polyurethane, phenol, and acrylic.
- the shaft 2 is press-fitted inside the magnet assembly 40. Therefore, by extending the core 3 radially outward from the inner circumferential surface of the core 3, It is possible to further tighten the coupling between the magnet assembly 40 and the shaft 2 by providing an allowance for coupling with the protective cover 8.
- FIG. 5 is a longitudinal sectional view of a rotor 1 ⁇ / b> A that uses a core 31 instead of the core 3.
- FIG. 6 is a schematic cross-sectional view showing a state where the magnet assembly 40 ⁇ / b> A is assembled using the core 31 temporarily installed on the dedicated jig 20. As shown in the figure, when the configuration of the core 31 having no flange is employed, the manufacture of the core 31 can be simplified, leading to cost reduction. In the manufacturing method of the rotor 1A, the above-described ST3 becomes the next ST3A.
- the first protective ring 6A is fixed on the core 31 using an adhesive.
- the first protection ring 6A is positioned in the axial direction using the end holding jig 20C, and the second protection ring 6 is added in the axial direction by the pressing jig 20A.
- the first protective ring 6A, the permanent magnet 4 and the second protective ring 6 are in close contact with each other in the axial direction without any gap.
- the length of the core in the axial direction according to the size of the rotor is the permanent magnet 4. If the length is larger than the axial length, a plurality of first protection rings 6A and a plurality of second protection rings 6 may be provided.
- the permanent magnet 4 was made into the lower permanent magnet 4A and the upper permanent magnet 4B which were divided into two in the axial direction, it may be configured to be divided into two or more, for example, three, or may not be divided.
- FIG. 7 is a longitudinal sectional view of a main part of a rotor 1C as a comparative example in which a space K exists between the permanent magnet 4 and the protective ring 6B.
- the rotating electrical machine including the rotor 1 according to the first embodiment operates at a rated rotation of 20000 RPM, for example, the first protective ring 6A, the second protective ring 6, the permanent magnet 4, and the spacer 5 are generated. Centrifugal force is applied to the protective cover 8.
- the rotor 1 has a configuration in which the space K which is the problem shown in FIG. 7 does not exist, intensive stress is not applied to the protective cover 8.
- the protective cover 8 it is possible to prevent the protective cover 8 from generating a shearing force due to the centrifugal force. As a result, the protective cover 8 can be prevented from being damaged, and the permanent magnet 4 can be reliably held.
- FIG. 8 is a diagram illustrating an assembly flow of the rotor 1 according to the second embodiment. Below, each step of a manufacturing method is shown. ST201.
- the shaft 2 is press-fitted into the core 3 (shaft press-fitting process).
- ST3 to ST6A Same as ST3 to ST6A in the first embodiment.
- the rotary drive device 30 is connected to the shaft 2 to rotate the shaft 2, and the CFRP fiber bundle is spirally wound in the axial direction (filament winding) and impregnated with an adhesive epoxy resin.
- the protective ring 6A, the permanent magnet 4, the spacer 5, and the second protective ring 6 are uniformly wound (fiber bundle winding step).
- ST7A to ST9A The same as in the first embodiment.
- ST10 of the first embodiment is not necessary.
- the rotor 1 shown in FIG. 1 is manufactured by the process as described above. Since the manufactured product is the same as the rotor 1 of the first embodiment, there is an effect that damage to the protective cover 8 can be prevented without applying intensive stress to the protective cover 8.
- FIG. 9 is a longitudinal sectional view of a main part of the rotor 301.
- FIG. 10 is a diagram illustrating an assembly flow of the rotor 301.
- ST9B and ST9C shown in FIG. 10 and the following are added after ST9A of the manufacturing method shown in the first embodiment, and a magnet assembly 340 is manufactured.
- the second protective ring 306 and the protective cover 8 are provided with an end surface step 13 whose end surface is recessed annularly in the axial direction by cutting using a machine (end surface step cutting step).
- An epoxy resin is applied to the end face step 13 and cured to form a coating 14 (end face step coating process).
- FIG. 11 is a schematic side view of the protective cover 8.
- the protective cover 8 is formed by so-called filament winding in which a CFRP fiber bundle 8A as shown in FIG. 11 is spirally wound in the axial direction. Cutting of the end face step 13 and coating processing are performed on the winding end side of the above-mentioned CFRP (CFRP is wound from the lower side to the upper side in FIG. 11). Thus, the cutting process on the protective cover 8 is performed to remove the CFRP winding end portion on the outermost layer surface of the protective cover 8. The state where the winding end portion is removed is the state shown in FIG. As shown in FIG.
- the end face of the second protective ring 306 is also cut simultaneously by the above-described machining. Providing such an end face step 13 prevents the CFRP fibers at the winding end of the outermost surface of the CFRP from being unwound. Further, the coating 14 has an effect of preventing the scattering of the fluff of CFRP fibers. Note that the winding end may be provided on either side in the axial direction.
- FIG. 12 is a longitudinal sectional view of a rotor 401 according to the fourth embodiment.
- FIG. 13 is a diagram illustrating an assembly flow of the rotor 401.
- the rotating electrical machine has a rating according to the application.
- the configuration corresponding to the 20,000 RPM class rotor 1 has been described. That is, since the shaft 2 is press-fitted into the core 3 and fixed, the remaining tightening force reduces the stress caused by the centrifugal force of the permanent magnet 4 applied to the protective cover 8.
- a rotor 401 in which the permanent magnet 4 is directly attached to the shaft 2 without providing the core 3 will be described.
- Other configurations are the same as those in the first embodiment.
- each step of the manufacturing method of the rotor 401 is shown. Since the core 3 is not used, there is no ST1 or ST2 performed in the first embodiment. ST403.
- the first protective ring 6A is attached to the outer peripheral surface of the shaft 2 using an adhesive (first protective ring bonding step).
- a plurality of lower permanent magnets 4A and spacers 5 are attached to the outer peripheral surface of the shaft 2 using an adhesive (lower permanent magnet and spacer bonding step). At this time, the lower permanent magnets 4A are arranged so that the N poles and the S poles are alternately placed in the circumferential direction via the spacers 5.
- the upper permanent magnet 4B and the spacer 5 are attached to the outer peripheral surface of the shaft 2 using an adhesive (upper permanent magnet and spacer bonding step).
- the second protective ring 6 is attached to the outer peripheral surface of the shaft 2 using an adhesive so as to be in contact with the axial end surface of the upper permanent magnet 4B (second protective ring bonding step).
- ST406A The pressurizing jig 20A and the end holding jig 20C are attached to the shaft 2, and the second protective ring 6 is pressed in the axial direction before the adhesive is cured (pressurizing process).
- the first protective ring 6A and the permanent magnet are connected to the shaft 2 by rotating the shaft 2 to rotate the shaft 2 and impregnating the CFRP fiber bundle with the epoxy resin for adhesion so as to traverse in the axial direction. 4, the spacer 5, and the second protective ring 6 are wound around the outer peripheral surface (fiber bundle winding step).
- a heat shrink tape is wound around the outer periphery of the wound CFRP fiber bundle (heat shrink tape winding step).
- a rotation drive device is removed (rotation drive device removal process).
- the epoxy resin is cured in a furnace (curing process). The following steps are the same as those in the first embodiment.
- the rotor 401 has a small number of parts and the manufacturing method is simplified, so that the low-cost rotor 401 corresponding to the application is provided. can do.
- FIG. 14 is a longitudinal sectional view of a rotating electrical machine 100 that uses the rotor 1.
- the rotor 1 shown in FIGS. 1 and 2 is rotatably supported inside a stator 50 by a bearing (not shown).
- the rotating electrical machine 100 can withstand high-speed rotation, for example, 20000 RPM, prevents radial deformation and damage at the end of the protective cover 8, and easily reinforces peeling of the permanent magnet 4. It is. In addition, since no space is left inside the axial end of the protective cover 8 in the radial direction, deformation in the radial direction is prevented, so that the magnetic gap between the stator 50 and the rotor 1 can be reduced to a normal level. From 1 mm or less, it is possible to set a smaller value, and there is an effect that it is possible to achieve high output and high efficiency of the rotating electrical machine 100.
- a preferable range is about 0.3 mm to 0.6 mm.
- the rotating electrical machine provided with the rotor 401 of the fourth embodiment corresponds to a lower speed rating than the rotor 1 of the first to third embodiments, and has good cost performance. There is an effect that a rotating electrical machine can be provided.
- FIG. 15 is a longitudinal sectional view of a main part of the rotor 601.
- the rotor 601 includes the inner peripheral surface of the protective cover 8 of the rotor 1 described in the first to third embodiments, the first protective ring (not shown), the permanent magnet 4, the spacer 5, and the second protective member.
- a thin plate member 9 formed in a cylindrical shape in contact with these members is provided between the outer peripheral surfaces of the ring 606.
- the thin plate member 9 is a non-magnetic material and is made of a material such as copper, stainless steel, or aluminum, but is not limited to these materials.
- the end face step 613 is provided by cutting using a machine tool for the first protective ring, the second protective ring 606, the protective cover 8, and the thin plate member 9. .
- the reason why the thin plate member 9 is additionally provided in the above-described place will be described below.
- the split surfaces of parts such as the permanent magnet 4, the spacer 5, and the second protective ring 606 are rounded or slightly stepped at the corners, or uneven due to dimensional errors due to manufacturing variations of parts. There is a case.
- the protective cover 8 is provided by additionally providing a thin plate member 9 between the inner peripheral surface of the protective cover 8 and the outer peripheral surfaces of the first protective ring, the permanent magnet 4, the spacer 5, and the second protective ring 606.
- a smooth surface is formed on the inner peripheral surface of the rotor, and the centrifugal force when the rotor 601 rotates is more uniformly applied to the portion of the protective cover 8 to prevent stress from being concentrated on the centrifugal force. It is possible to prevent the shearing force due to the occurrence of the protective cover 8 and to obtain the same effect as in the first embodiment more reliably.
- the CFRP or GFRP is wound, wrinkles due to steps or irregularities are hardly formed, and the protective cover 8 having high strength and high reliability can be obtained.
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- Permanent Field Magnets Of Synchronous Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Description
このような空間を有する回転子は、高速回転時において、永久磁石端面のCFRP層が応力集中によって破損する懸念があるという問題点がある。
シャフトの周囲に、周方向に等間隔に分割され、軸方向に設けられた複数の永久磁石と、
前記永久磁石の軸方向の一端を位置決めして保持する第一保護リングと、
前記永久磁石の軸方向の他端を位置決めして保持する第二保護リングと、
前記永久磁石と、前記第一保護リングと、前記第二保護リングの外周面を覆う径方向に均一の厚みを有する保護カバーとを備えたものである。
固定子と、
前記固定子の内側に回転可能に軸支された、上述の回転子とからなるものである。
前記第一保護リングと、前記永久磁石と、前記第二保護リングとを軸方向に密着させる加圧工程を有するものである。
以下、実施の形態1による回転子、回転子の製造方法を図を用いて説明する。
図1は、実施の形態1による回転子1の縦断面図である。
図2は、図1のX-X横断面図である。
図1および図2に示すように、回転子1は、シャフト2に設けられ、コア3の一方端に、径方向に張り出したフランジ3Aが形成された筒状のコア3と、このコア3の外周面に複数個、すなわち、周方向に分割され等間隔で交互にN極S極となるようにスペーサ5を介して軸方向に配設された永久磁石4とを備える。また、永久磁石4は、軸方向に2分割され、図1の紙面下部に設けられた4個の下部永久磁石4Aと、上部に設けられた4個の上部永久磁石4Bとの合計8個の永久磁石からなる。スペーサ5も、永久磁石4と同様に軸方向に2分割されていてもよい。永久磁石4の図2に示す断面形状は円弧状であり、スペーサ5の断面形状は矩形状である。スペーサ5は、永久磁石4と同じ軸方向の長さを有し、隣り合う永久磁石4間の隙間を埋める。なお、スペーサ5が無く、かつ周方向に隙間無く永久磁石4が分割して配置された構成でも回転子1として機能する。
図3は、専用治具20上に仮設置したコア3を用いて、磁石組立体40を組み立てた状態を示す断面模式図である。
図4は、磁石組立体40を備える回転子1の組み立てフローを示す図である。
ここで、磁石組立体40とは、コア3の外周面に第一保護リング6Aと、第二保護リング6と、永久磁石4と、スペーサ5と、保護カバー8とが一体化して形成されたものをいう。以下、各ステップ(STと略す)毎に製造方法を述べる。
ST1.回転駆動装置30に専用治具20を設置する(治具設置工程)。
ST2.図示しない固定具で専用治具20にコア3を固定する(コア固定工程)。
ST3.コア3のフランジ3Aに接するように第一保護リング6Aを設置する(第一保護リング設置工程)。
ST4.複数の下部永久磁石4Aとスペーサ5とを、第一保護リング6Aに、それぞれの下端部が接するように、コア3の外周面に接着剤を用いて貼り付ける(下部永久磁石、スペーサ接着工程)。この際、スペーサ5を介して下部永久磁石4Aは、周方向にN極とS極とが交互に置かれるよう配置される。
ST5.ST4と同様にして、複数の上部永久磁石4Bとスペーサ5とを接着剤を用いて、コア3の外周面に貼り付ける(上部永久磁石、スペーサ接着工程)。
ST6.接着剤を用いて第二保護リング6を、上部永久磁石4Bの軸方向端面に接するように、コア3の外周面に貼り付ける(第二保護リング接着工程)。
ST6A.第二保護リング6を軸方向に加圧する加圧治具20Aを、第二保護リング6の軸方向上方に取り付けて、接着剤が硬化する前に第二保護リング6を軸方向に加圧する(加圧工程)。これにより、第一保護リング6Aと、永久磁石4と、第二保護リング6とが軸方向に隙間無く密着固定される。
ST7.回転駆動装置30を動作させ、専用治具20を回転駆動させ、ガラス繊維又は炭素繊維からなる繊維束を軸方向に螺旋状に巻回(フィラメントワインディング)し、接着用のエポキシ系樹脂を含浸させながら、第一保護リング6Aと、永久磁石4と、スペーサ5と、第二保護リング6の外周面上に均一に巻き付ける(繊維束巻付工程)。巻き付け方向は、図3、紙面上から下へ向かってでも良いし、下から上へ向かってでも良い。なお、繊維束に樹脂を含浸させながら巻きつけるのではなく、あらかじめ樹脂が含浸されたテープ状の繊維材を用いても良い。このとき、端部規制治具20Bにより、繊維束を巻回する範囲を軸方向の両側から規制する。これにより、繊維材に含浸された樹脂が軸方向へ拡がることを防止できる。
ST7A.巻き付けられたCFRPの繊維束の外周に、熱によって収縮する熱収縮テープ(図示せず)を巻き付ける(熱収縮テープ巻付工程)。この熱収縮テープによって周方向への樹脂のタレを防止する。これにより、均一な厚みを有する保護カバー8を得ることができる。
ST8.炉中でエポキシ系樹脂を硬化させる(硬化工程)。
ST9.一体的に固着された磁石組立体40を専用治具20から取りはずす(取出工程)。
ST9A.磁石組立体40の外周から熱収縮テープを取りはずす(熱収縮テープ除去工程)。
ST10.磁石組立体40にシャフト2を圧入により嵌め込み固定することで図1に示す回転子1が製造される(シャフト圧入工程)。
ここでは、強度、剛性の観点からエポキシ系樹脂を用いている。その他に、ビニルエステル、不飽和ポリエステル、ポリウレタン、フェノール、アクリルでも良好な性能が得られる。
図5は、コア3に替えてコア31を利用した回転子1Aの縦断面図である。
図6は、専用治具20上に仮設置したコア31を用いて、磁石組立体40Aを組み立てた状態を示す断面模式図である。
図のように、フランジの存在しないコア31の構成を採用すると、コア31の製作が簡単化でき、コスト低減につながる。回転子1Aの製造方法は、上述のST3が、次のST3Aとなる。
また、この場合、図6に示すように、端部保持治具20Cを用いて第一保護リング6Aを軸方向に位置決めして、加圧治具20Aにより第二保護リング6を軸方向に加圧して第一保護リング6Aと、永久磁石4と、第二保護リング6とが、軸方向に隙間無く密着される。
実施の形態1による回転子1を備えた回転電機が、例えば20000RPMの定格回転で動作する際、第一保護リング6Aと、第二保護リング6と、永久磁石4と、スペーサ5とに発生する遠心力が、保護カバー8に加わる。しかしながら、回転子1は、図7に示された問題点である空間Kが存在しない構成であるので、保護カバー8に集中的な応力が印加されることがない。
以下、実施の形態2による回転子、回転子の製造方法を図を用いて説明する。
実施の形態1では、専用治具20を用いて磁石組立体40を作成する例を示したが、この実施の形態2では、以下の工程に示す製造方法によって回転子1を作成する。すなわち、専用治具20を使用することなく、最初に、コア3にシャフト2を圧入してから磁石組立体40を形成することで、図1の回転子1が製造される。
図8は、実施の形態2における回転子1の組み立てフローを示す図である。
以下に、製造方法の各ステップを示す。
ST201.コア3にシャフト2に圧入する(シャフト圧入工程)。
ST3~ST6A.実施の形態1のST3~ST6Aと同じ。
ST207.シャフト2に回転駆動装置30を連結してシャフト2を回転駆動させ、CFRPの繊維束を軸方向に螺旋状に巻回(フィラメントワインディング)し、接着用のエポキシ系樹脂を含浸させながら、第一保護リング6Aと、永久磁石4と、スペーサ5と、第二保護リング6の外周面上に均一に巻き付ける(繊維束巻付工程)。
ST7A~ST9A.実施の形態1と同様である。
本実施の形態では、実施の形態1のST10は必要ない。以上のような工程で図1に示す回転子1が製造される。なお、製造した物は、実施の形態1の回転子1と同じ物なので、保護カバー8に集中的な応力が印加されることなく、保護カバー8の損傷発生を防止出来る効果がある。
以下、実施の形態3による回転子、回転子の製造方法を図を用いて説明する。
図9は、回転子301の要部縦断面図である。
図10は、回転子301の組み立てフローを示す図である。
この実施の形態3における回転子の製造方法では、実施の形態1で示した製造方法のST9Aの後に、図10及び以下に示す、ST9BとST9Cとを追加し、磁石組立体340を製作する。
ST9B.第二保護リング306と、保護カバー8とに機械を用いた切削加工によって、外周側が軸方向に環状に凹んだ端面段差13を設ける(端面段差切削工程)。
ST9C.端面段差13にエポキシ系樹脂を塗布、硬化させ、コーティング14を形成する(端面段差コーティング工程)。
図11は、保護カバー8の側面模式図である。
保護カバー8は、図11に示すようなCFRPの繊維束8Aを軸方向に螺旋状に巻き付けるいわゆるフィラメントワインディングで形成している。端面段差13の切削加工及び、コーティング処理は、上述のCFRPの巻き終わり側に施されている(CFRPは、図11、紙面下側から上側に向かって巻かれている)。このように、保護カバー8に対する切削加工は、保護カバー8の最外層表面のCFRPの巻き終わり端部を除去するために行っている。巻き終わり端部を除去した状態が、図11に示す状態である。なお、図9に示すように、第二保護リング306の端面も前述の機械加工によって同時に切削されている。このような端面段差13を設けることで、CFRPの最外層表面の巻き終わり端部のCFRPの繊維が解けてくる懸念を防止している。また、コーティング14によりCFRPの繊維の毛羽の飛散を防止するという効果がある。なお、巻き終わり端部は、軸方向のどちら側に設けてもよい。
以下、実施の形態4による回転子、回転子の製造方法を図を用いて説明する。
図12は、実施の形態4による回転子401の縦断面図である。
図13は、回転子401の組み立てフローを示す図である。
回転電機は、用途に応じた定格がある。前述した実施の形態1~実施の形態3では、20000RPM級の回転子1に対応した構成を説明した。つまり、シャフト2をコア3に圧入して固定しているので、その残存する締付力により、保護カバー8に印加される永久磁石4の遠心力による応力を低減している構成であった。この実施の形態4では、コア3を設けることなく、シャフト2上に直接永久磁石4を貼り付けた回転子401について説明する。その他の構成は、実施の形態1と同様である。
コア3は使用しないので、実施の形態1で行った、ST1,ST2は無い。
ST403.接着剤を用いて第一保護リング6Aをシャフト2の外周面に貼り付ける(第一保護リング接着工程)。
ST404.接着剤を用いて複数の下部永久磁石4Aとスペーサ5とをシャフト2の外周面に貼り付ける(下部永久磁石、スペーサ接着工程)。この際、スペーサ5を介して下部永久磁石4Aは、周方向にN極とS極とが交互に置かれるよう配置される。
ST405.ST404と同様にして、接着剤を用いて上部永久磁石4Bとスペーサ5とをシャフト2の外周面に貼り付ける(上部永久磁石、スペーサ接着工程)。
ST406.接着剤を用いて第二保護リング6を、上部永久磁石4Bの軸方向端面に接するように、シャフト2の外周面に貼り付ける(第二保護リング接着工程)。
ST406A.加圧治具20Aと、端部保持治具20Cとをシャフト2に取り付けて、接着剤が硬化する前に第二保護リング6を軸方向に加圧する(加圧工程)。
ST407.シャフト2に回転駆動装置30を連結してシャフト2を回転駆動させ、CFRPの繊維束を軸方向にトラバースするように接着用のエポキシ系樹脂を含浸させながら、第一保護リング6Aと、永久磁石4と、スペーサ5と、第二保護リング6の外周面上に巻き付ける(繊維束巻付工程)。
ST7A.巻き付けられたCFRPの繊維束の外周に熱収縮テープを巻き付ける(熱収縮テープ巻付工程)。
ST7B.回転駆動装置を取り外す(回転駆動装置取り外し工程)。
ST8.炉中でエポキシ系樹脂を硬化させる(硬化工程)。
以下の各工程は、実施の形態1と同様である。
以下、実施の形態5による回転電機100を図を用いて説明する。
図14は、回転子1を用いる回転電機100の縦断面図である。
図に示すように、回転電機100は、固定子50の内側に、図1、2に示す回転子1が、図示しない軸受けにより、回転可能に軸支されている。
以下、実施の形態5による回転子を図を用いて説明する。
図15は、回転子601の要部縦断面図である。
回転子601は、実施の形態1~実施の形態3で説明した回転子1の保護カバー8の内周面と、第一保護リング(図示せず)、永久磁石4、スペーサ5及び第二保護リング606のそれぞれの外周面との間に、これらの部材に接する円筒形状に成形した薄板部材9を備える。
従って、例示されていない無数の変形例が、本願に開示される技術の範囲内において想定される。例えば、少なくとも1つの構成要素を変形する場合、追加する場合または省略する場合、さらには、少なくとも1つの構成要素を抽出し、他の実施の形態の構成要素と組み合わせる場合が含まれるものとする。
Claims (13)
- シャフトの周囲に、周方向に等間隔に分割され、軸方向に設けられた複数の永久磁石と、
前記永久磁石の軸方向の一端を位置決めして保持する第一保護リングと、
前記永久磁石の軸方向の他端を位置決めして保持する第二保護リングと、
前記永久磁石と、前記第一保護リングと、前記第二保護リングの外周面を覆う径方向に均一の厚みを有する保護カバーとを備えた回転子。 - 前記保護カバーは、軸方向に、螺旋状に巻回された炭素繊維強化プラスチック又はガラス繊維強化プラスチックからなる請求項1に記載の回転子。
- 前記保護カバーの軸方向端部と、
少なくとも前記第一保護リングと前記第二保護リングとの一方の軸方向端部の一方とには、外周側が軸方向に環状に凹んだ端面段差が形成され、
前記端面段差は、樹脂によりコーティングされている請求項1又は請求項2に記載の回転子。 - 前記第一保護リングおよび前記永久磁石および前記第二保護リングの外周面と、
前記保護カバーの内周面との間に、
前記第一保護リングおよび前記永久磁石および前記第二保護リングの外周面と、
前記保護カバーの内周面とに接する、非磁性材料からなる円筒形状の薄板部材を備えた請求項1から請求項3のいずれか1項に記載の回転子。 - 周方向に隣り合う前記永久磁石の間には、前記永久磁石間の隙間を埋めるスペーサが設けられている請求項1から請求項4のいずれか1項に記載の回転子。
- 前記第一保護リングと、前記永久磁石と、前記第二保護リングとは、前記シャフトに接着剤で貼り付けられている請求項1から請求項5のいずれか1項に記載の回転子。
- 前記永久磁石と、前記第二保護リングとは、前記シャフトの周囲に嵌合される筒状のコアに接着剤で貼り付けられている請求項1から請求項5のいずれか1項に記載の回転子。
- 前記コアの軸方向の一端に径方向に張り出したフランジを備え、前記第一保護リングは、前記フランジに、軸方向に接している請求項7に記載の回転子。
- 固定子と、
前記固定子の内側に回転可能に軸支された、請求項1から請求項8のいずれか1項に記載の回転子とからなる回転電機。 - 請求項1から請求項8のいずれか1項に記載の回転子の製造方法であって、
前記第一保護リングと、前記永久磁石と、前記第二保護リングとを軸方向に密着させる加圧工程を有する回転子の製造方法。 - 請求項2に記載の回転子の製造方法であって、
前記第一保護リングと、前記永久磁石と、前記第二保護リングの外周面に、
ガラス繊維又は炭素繊維の繊維束を、軸方向に螺旋状に、接着用の樹脂を含浸させながら、均一に巻き付ける繊維束巻付工程を有する回転子の製造方法。 - 前記繊維束巻付工程において、端部規制治具により、前記繊維束を巻回する範囲を軸方向の両側から規制する請求項11に記載の回転子の製造方法。
- 請求項3に記載の回転子の製造方法であって、
前記第一保護リングと、前記永久磁石と、前記第二保護リングの外周面に、
ガラス繊維又は炭素繊維の繊維束を、軸方向に螺旋状に、接着用の樹脂を含浸させながら、均一に巻き付ける繊維束巻付工程と、
前記繊維束の巻き終わり側の端部に、前記端面段差を切削加工により設ける端面段差切削工程と、
前記端面段差を樹脂によりコーティングする、端面段差コーティング工程とを有する回転子の製造方法。
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JP2021052485A (ja) * | 2019-09-24 | 2021-04-01 | 株式会社デンソー | 回転電機 |
EP4145680A1 (en) * | 2021-09-03 | 2023-03-08 | Skf Magnetic Mechatronics | Rotary electrical machine and rotor for such machine |
EP4145682A1 (en) * | 2021-09-03 | 2023-03-08 | SKF Magnetic Mechatronics | Rotary electrical machine and stator assembly for such machine |
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WO2020209051A1 (ja) * | 2019-04-10 | 2020-10-15 | 株式会社Ihi | モーターローター |
CN113178967B (zh) * | 2021-04-30 | 2023-04-07 | 哈尔滨工业大学 | 大功率高速永磁同步电机转子 |
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Also Published As
Publication number | Publication date |
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JPWO2018221008A1 (ja) | 2019-11-07 |
CN110663159A (zh) | 2020-01-07 |
US11489385B2 (en) | 2022-11-01 |
KR20190137901A (ko) | 2019-12-11 |
KR102218809B1 (ko) | 2021-02-22 |
CN110663159B (zh) | 2021-08-20 |
JP6804642B2 (ja) | 2020-12-23 |
US20200119606A1 (en) | 2020-04-16 |
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